Friction in sheet metal forming: influence of surface roughness and strain rate on sheet metal forming simulation results

Sigvant, Mats; Pilthammar, Johan; Hol, J.; Wiebenga, J.H.; Chezan, Toni; Carleer, B.D.; Boogaard, A.H. van den

doi:10.1016/j.promfg.2019.02.169

Cited by 60 publications

(49 citation statements)

References 7 publications

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“…Nine's drawbead simulator mainly tests the friction condition between the blankholder and the die, which fails to reflect the change of coefficient of friction (COF) in each region caused by different stress modes. Several authors have conducted research to better understand the frictional phenomena in sheet metal forming [10][11][12][13] and mechanics of sheet deformation at the drawbeads [14][15][16] and over the years, analytical, semi-empirical and numerical approaches have been developed.…”

Section: Introductionmentioning

confidence: 99%

A 3D FEM-Based Numerical Analysis of the Sheet Metal Strip Flowing Through Drawbead Simulator

Trzepieciński

Fejkiel

2019

Metals

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Drawbeads are elements of the stamping die and they are used to compensate material flow resistance around the perimeter of the drawpiece or to change the stress state in specific regions of the drawpiece. This paper presents the results of experimental and numerical analyses of tests of sheet metal flowing through a drawbead. The tests have been carried out using a special tribological simulator of the drawbead. Experimental tests to determine the coefficient of friction (COF) have been carried out for three widths of sheet metal strip and two drawbead heights. The three-dimensional (3D) elastic-plastic numerical computations were performed using the MSC. Marc program. Special attention was given to the effect of material flow through the drawbead on the distribution of the normal stress on the tool-sheet interface. The mesh sensitivity analysis based on the value of the drawing force of the specimen being pulled through the drawbead allowed an optimal mesh size to be determined. The errors between the numerically predicted values of the COF and the values experimentally determined ranged from about 0.95% to 7.1% in the cases analysed. In the case of a drawbead height of 12 mm, the numerical model overestimated the value of the COF for all specimen widths analysed. By contrast, in the case of a drawbead height of 18 mm, all experimentally determined friction coefficients are underestimated by Finite Element Method (FEM). This was explained by the different character of sheet deformation under friction and frictionless conditions. An increase in the drawbead height, with the same sheet width, increases the value of the COF.Metals 2020, 10, 45 2 of 15 by Nine [9]. Nine's drawbead simulator mainly tests the friction condition between the blankholder and the die, which fails to reflect the change of coefficient of friction (COF) in each region caused by different stress modes. Several authors have conducted research to better understand the frictional phenomena in sheet metal forming [10][11][12][13] and mechanics of sheet deformation at the drawbeads [14-16] and over the years, analytical, semi-empirical and numerical approaches have been developed.

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Section: Introductionmentioning

confidence: 99%

A 3D FEM-Based Numerical Analysis of the Sheet Metal Strip Flowing Through Drawbead Simulator

Trzepieciński

Fejkiel

2019

Metals

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“…Apart from material behaviour, friction between the die and sheet also plays a key aspect in drawing operations. According to previous research, this friction was highly dependent on the lubricant, sheet, die surface roughness and material, as well as on contact pressure, sliding velocity and temperature [7].…”

Section: Friction Characterizationmentioning

confidence: 82%

“…Other studies showed that this phenomenon, which appeared to be related to dislocation pile-up [13], increased springback after forming [14]. The friction conditions during draw-in of the material were shown to be equally important [7].…”

Section: Introductionmentioning

confidence: 87%

“…Traditionally, aeronautical components are characterized by a very streamlined and small curvature design and are manufactured with high-or very-high-strength material. These two features increase the springback after forming exponentially [7]. To address these issues, thermal treatments (TTs) are commonly employed in an effort to reduce residual stresses or improve formability.…”

Section: Introductionmentioning

confidence: 99%

“…Previous research demonstrated the importance of finite element methods in efficient design and optimization of cold stamping processes [7]. In recent years, much effort has focused on the modelling of aeronautical-grade stamping operations [8].…”

Section: Introductionmentioning

confidence: 99%

See 2 more Smart Citations

Experimental and Numerical Simulation Investigation on Deep Drawing Process of Inconel 718 with and without Intermediate Annealing Thermal Treatments

Ulibarri¹,

Galdos²,

Argandoña³

et al. 2020

Applied Sciences

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The aeronautical industry is moving from high-capacity large-airplane construction to low-capacity small-airplane construction. With the change in the production volume, there is a need for more efficient manufacturing processes, such as stamping/deep drawing. However, the streamlined shape and exotic materials of airplanes pose a challenge to accurate numerical simulation of the manufacturing processes. In the case of the Inconel 718 material, researchers previously proposed numerical models; however, these models failed to take account of some key parameters, such as the degradation of the elastic modulus and intermediate annealing thermal processes. The aim of the present study was to characterize the Inconel 718 material, with and without intermediate annealing thermal treatment (TT) and to propose a suitable model. To evaluate the accuracy of the proposed model, a U-drawing benchmark test was used.

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Analytical Approach to Failure Determination of Advanced High‐Strength Steel in Stretch‐Bending Mode

Lee

Barlat

2020

steel research int.

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Experimental and analytical studies on the stretch‐bending characteristics of advanced high‐strength steel sheets, primarily used in the automotive industry, are conducted. Herein, the stretch‐bending test, in which a specimen fixed at both ends is bent at its center with sharp punches until failure occurs, is conducted. Assuming that the failure of the material occurred at the maximum tensile force, a relationship between applied force and forming height is derived. Nine steels including high‐strength low‐alloy, dual‐phase, and transformation‐induced plasticity steels are tested, and the calculated results are compared with experimental limit‐forming heights. Finally, a failure criterion based on process variables and tensile properties of the material is proposed based on the deformation in the sheet thickness direction.

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Friction in sheet metal forming: influence of surface roughness and strain rate on sheet metal forming simulation results

Cited by 60 publications

References 7 publications

A 3D FEM-Based Numerical Analysis of the Sheet Metal Strip Flowing Through Drawbead Simulator

A 3D FEM-Based Numerical Analysis of the Sheet Metal Strip Flowing Through Drawbead Simulator

Experimental and Numerical Simulation Investigation on Deep Drawing Process of Inconel 718 with and without Intermediate Annealing Thermal Treatments

Analytical Approach to Failure Determination of Advanced High‐Strength Steel in Stretch‐Bending Mode

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