FE-analysis and in situ visualization of pressure-, slip-rate-, and temperature-dependent coefficients of friction for advanced sheet metal forming: development of a novel coupled user subroutine for shell and continuum discretization

Klocke, Fritz; Trauth, Daniel; Shirobokov, Anton; Mattfeld, Patrick

doi:10.1007/s00170-015-7184-1

Cited by 28 publications

(21 citation statements)

References 13 publications

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“…In addition, due to the outstanding performance of numerical simulation technology in shortening the product design cycle and saving production costs, it has been widely used in the optimization design of sheet metal forming [3]. The accuracy of the simulation results depends on the correct contact model, where the friction model occupies a decisive role.…”

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confidence: 99%

Analysis of Sheet Metal Forming (Stamping Process): A Study of the Variable Friction Coefficient on 5052 Aluminum Alloy

Dou

Xia

2019

Metals

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Under a boundary lubrication regime, the effect of sliding velocity and normal loads on the friction coefficient in the sheet metal stamping process was investigated using a pin-on-disk sliding wear test. Software was used to analyze both the data generated and the friction coefficient; in addition, a variable friction model based on different velocities and normal loads was also initiated. Under different experimental conditions and numerous influences, both the analysis and microtopography examination of sheet metal helped to obtain the mechanism influence on the friction coefficient. Through further analysis of the microtopography of sheet metal, the law of the surface roughness of sheet metal after grinding with stamping die was established. The model was established to simulate the thickness distribution and spring-back of U-bend parts using ABAQUS software. The results show that the friction coefficient values between the sheet metal and the stamping die generally decrease with increasing sliding velocity and normal loads, and the decreasing tendency slows down under a higher sliding velocity and normal load. Furrow wear and abrasive wear are the main wear mechanisms, with slight sticking wear under the boundary lubrication; the surface roughness after grinding with stamping die generally increases with increasing normal loads and decreasing sliding velocity. The predicted results of thickness distribution with a constant friction coefficient of 0.1 and with the variable friction coefficient model are more consistent with the actual measured values, but the predicted accuracy of spring-back in the variable friction coefficient model is higher than that of the constant friction coefficient model. Sheet metals are widely applied in the automotive, ship-building and aerospace industries, and have high potential for energy conservation, emission reduction, and safety improvement, but also comes with many new problems. In many cases, due to their poor plasticity at room temperature, defects are easily created in the forming process, such as wrinkling, cracking, poor forming accuracy, and spring-back [1]. At present, regarding the optimal way of forming steel plates to solve these problems, the optimization method for the forming process cannot be effective because of the different properties of the sheet metal, which lead to a longer life cycle and a higher product cost. Studies have shown that material properties, processing techniques, and friction are the main factors which affect the formability and the quality of the parts. The effect of the processing techniques on the formability of the sheet is achieved mainly through changing the friction between the sheet metal and the stamping die. Friction mainly affects the formability of the sheet by changing the stress distribution in the

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confidence: 99%

Analysis of Sheet Metal Forming (Stamping Process): A Study of the Variable Friction Coefficient on 5052 Aluminum Alloy

Dou

Xia

2019

Metals

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“…Incorporating the required subroutines (VUMAT, VFRICTION, and VUFIELD) with multi-thread computation, this was achieved using common blocks. Using mpi threads did not require a locking and unlocking function in order for the computation to work correctly [ 34 ].…”

Section: Dynamic Friction Implementationmentioning

confidence: 99%

Development of a Novel Friction Model for Machining Simulations in Unidirectional Composite Materials

et al. 2022

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Constant coefficients of friction (COFs) are currently used in the literature to describe the contact mechanics between tool and workpiece for finite element (FE) machining simulation of carbon fibre-reinforced polymers (CFRPs). However, these are solely based on closed-loop tribology experimentation, which insufficiently represent machining conditions. To overcome this gap in the knowledge, this work proposes a novel experimental open-loop tribological testing method to produce a dynamic FE friction model for CFRP machining simulations. The newly proposed dynamic friction model is based on a function of fibre angle, contact pressure and slip rate, and it has been validated to both experimental results and constant COF FE simulations. The main aim of this article is to create a link between machining, tribology and FE simulation, by implementing cutting-edge tribological testing that results in highly accurate FE simulations. This dynamic model has been shown to improve the accuracy of open-loop tribological simulations, giving confidence in future implantation in CFRP machining simulations.

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“…It has since been commercialized in the software TriboForm. Another frictional model implemented in Abaqus [21] takes contact pressure, slip-rate and temperature into account. The implementation also makes it possible for die designers to visualize the coefficient of friction (COF) at different stages of the forming process to make better decisions about local surface treatment of the die.…”

Section: Simulation and Analysismentioning

confidence: 99%

Stamping Tools for Sheet Metal Forming: Current State and Future Research Directions

Jonsson

Stolt

Elgh

2020

Advances in Transdisciplinary Engineering

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Sheet metal forming tools play an important role in the manufacturing of many products. With shorter product life cycles and demand for shorter time to market for new products, the process for design and manufacturing of stamping tools becomes a critical part. Stamping dies are often designed and manufactured by smaller, specialized companies. For a tooling company, knowledge and experience is an important competitive advantage. Traditionally the design process has been characterized by being based on few key individuals with much experience and craftsmanship. To stay competitive in this market there is a need for more efficient processes, systems, tools and supports in order to become more industrialized. This paper presents results from a study of the state of practice in industry within progressive stamping tool design as well as a review of relevant literature. The design and manufacturing processes for stamping dies in six companies have been investigated through semi-structured interviews, from which the main challenges in the current state for the companies are identified. The results from the interviews was analyzed and compared to the established concepts and frameworks of methods found in the literature review. The results and analysis points in the direction of efforts needed in supporting the formalization and reuse of information and knowledge from previous tool projects and production, especially during the critical steps of tool process planning and creating the tool layout.

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FE-analysis and in situ visualization of pressure-, slip-rate-, and temperature-dependent coefficients of friction for advanced sheet metal forming: development of a novel coupled user subroutine for shell and continuum discretization

Cited by 28 publications

References 13 publications

Analysis of Sheet Metal Forming (Stamping Process): A Study of the Variable Friction Coefficient on 5052 Aluminum Alloy

Analysis of Sheet Metal Forming (Stamping Process): A Study of the Variable Friction Coefficient on 5052 Aluminum Alloy

Development of a Novel Friction Model for Machining Simulations in Unidirectional Composite Materials

Stamping Tools for Sheet Metal Forming: Current State and Future Research Directions

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