Improving stamping simulation accuracy by accounting for realistic friction and lubrication conditions: Application to the door-outer of the Mercedes-Benz C-class Coupé

Hol, J.; Wiebenga, J.H.; Stock, Julius; Wied, Johannes; Wiegand, Klaus; Carleer, B.D.

doi:10.1088/1742-6596/734/3/032091

Cited by 6 publications

(3 citation statements)

References 2 publications

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“…This demonstrates its effectiveness in AADD variable COF simulation. Since 2016, there is an extensive collaboration on friction modelling between Volvo cars [135][136][137][138][139][140][141][142], Mercedes-Benz cars [133,143], Ford cars [144], Renault cars [145], Opel cars [5,146], and TriboForm engineering. The involved automotive panels are Volvo's inner door, front door ringframe, A-pillar reinforcement panel, and fender, Mercedes-Benz's door-outer and front fender, Ford's hood inner panel, Renault's trunk lid inner part, and Opel's spare wheel well.…”

Section: Variable Cof Simulationmentioning

confidence: 99%

Advances in friction of aluminium alloy deep drawing

Gao

Zhao

et al. 2023

Friction

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Broad use of lightweight aluminium alloy parts in automobile manufacturing, aerospace, electronic communication, and rail transit is mainly formed through deep drawing process. Deep drawing friction is a key boundary condition for controlling the forming quality of aluminium alloy parts. However, due to the oxidation and adhesion tendency of aluminium alloys, the tribological situations of aluminium alloy deep drawing (AADD) system is more complicated than those of traditional deep drawing of steel sheets. Therefore, the study of AADD friction is essential for manufacturing high-performance aluminium alloy parts. Herein, aiming to provide a valuable reference for researchers in related fields, a comprehensive review of AADD friction is provided, including friction mechanism, influencing factors, friction measurement, friction model, friction simulation, and lubrication-free friction control. Finally, a brief conclusion and several current challenges were discussed.

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Section: Variable Cof Simulationmentioning

confidence: 99%

Advances in friction of aluminium alloy deep drawing

Gao

Zhao

et al. 2023

Friction

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“…Alaitz Zabala [20] illustrated the intricate nature of tribological systems and their impact on forming simulations, highlighting the necessity of incorporating the influence of process variables on the friction coefficient. Utilizing advanced friction models [21,22], it is possible to predict real-time friction coefficient values in simulations rather than assuming a uniform friction coefficient for all the elements of a blank. These models calculate friction coefficients for predefined process parameters that include local contact pressure, relative sliding velocity, plastic strain in the sheet material, and interface temperature.…”

Section: Introductionmentioning

confidence: 99%

Effect of Process Variables on Interface Friction Characteristics in Strip Drawing of AA 5182 Alloy and Its Formability in Warm Deep Drawing

Shrivastava,

Digavalli

2023

JMMP

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Warm forming is widely used to enhance the formability of aluminum alloy sheets. In warm deep drawing, the process variables significantly affect frictional characteristics at the tool–blank interface. It has been a conventional approach to use a constant value of friction coefficients in the finite element (FE) simulations. However, this can occasionally result in suboptimal accuracy of the predictions. In the present work, strip drawing tests were carried out on AA5182 aluminum alloy sheets to investigate the effect of important process variables, namely, temperature, contact pressure, and drawing speed, on the friction coefficient in the warm forming temperature range (100–250 °C) under lubricated condition. The results obtained from the strip drawing tests were used for defining the friction conditions in the simulation of warm deep drawing of cylindrical cups incorporating the variation of the friction coefficient with contact pressure and speed at different temperatures. The Barlat89 yield criterion was used to define the effect of anisotropy in the material. The Voce hardening law and Cowper–Symonds model were used to incorporate the effect of strain hardening and strain rate, respectively, in the simulation. Drawability and peak force were compared with the predictions when a constant friction coefficient was assumed. Warm deep drawing experiments were conducted to validate the predicted drawability and load–displacement curves. It is clearly observed that the accuracy of prediction of the limiting drawing ratio and peak load through simulations is improved by incorporating the effect of pressure and speed on friction coefficient as it captures the local variations of friction during warm deep drawing precisely, rather than assuming a constant average friction coefficient at all the tool–blank contact areas.

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“…The part quality is significantly determined by a variety of influencing parameters and their consideration in the sheet metal forming simulation. Recent research in the field of process simulation in sheet metal forming is therefore concerned, among others, with the modeling of materials [1], the representation of friction conditions by increasingly complex modeling approaches and the investigation [2][3][4], prediction and compensation of flange spring back [5,6]. However, all this work does ignore the fact that all the issues covered may have their origin in the definition of contact condition between the die and the blank.…”

Section: Intr Introduction Oductionmentioning

confidence: 99%

Modelling real contact areas caused by material straining effects in sheet metal forming simulation

Essig¹,

Liewald²,

Burkart³

et al. 2021

Esaform 2021

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Shortened product development processes in automotive industry combined with the upcoming lack of experts do challenge sheet metal part production fundamentally. Tryout time and manufacturing costs of large forming dies today are significantly influenced by their digitally supported engineering. The forming process by such tools is beside other influences is affected by elastic deformations of forming dies and press structure as well as contact areas between die and sheet metal part. In deep drawing such contact areas are influenced by the blank properties and the flange behavior in terms of thickening and thinning. Recent developments in sheet metal forming simulation do consider advanced friction models and structural modeling of die and press components improving simulation accuracy. Nevertheless thinning or thickening of sheet metal results into localized surface pressure distribution during deep drawing. For this reason, it is not sufficient to use the currently common practice of homogeneous surface pressure distribution in sheet metal forming simulation. In this respect, this paper presents a numerical approach for consideration of straining effects in the sheet metal part during forming operation. For this purpose, a systematic process improvement was developed in this paper to identify contact areas via a numeric simulation parameter. Validating the numerical investigation, a rectangle cup die is used, considering major strain. The main results of this contribution for that reason show how simulated contact areas can be estimated by reverse engineering of real forming parts. Hereby straining based contact areas lead to a novel contact area design in process planning, resulting in efficient die tryout.

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Improving stamping simulation accuracy by accounting for realistic friction and lubrication conditions: Application to the door-outer of the Mercedes-Benz C-class Coupé

Cited by 6 publications

References 2 publications

Advances in friction of aluminium alloy deep drawing

Advances in friction of aluminium alloy deep drawing

Effect of Process Variables on Interface Friction Characteristics in Strip Drawing of AA 5182 Alloy and Its Formability in Warm Deep Drawing

Modelling real contact areas caused by material straining effects in sheet metal forming simulation

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