Numerical Hybrid Fluid Structure Coupling: Application to Mixed Lubrication in Metal Forming

Abstract:

The present paper deals with a sequential fluid structure coupling approach in order to solution the roughness prediction. The cold rolling model involves the strip with its asperities, the lubricant and the working roll. The strip asperities are modeled in 2D (trapezoidal shape) forming valleys and plateaus. Fluid flow rate between each valley full of lubricant is solved using local Couette's equation. Thus, the volume of lubricant trapped and its pressure are updated on the cold rolling model. During computations, the asperity is deformed from the entry to the exit to obtain its final shape. Global parameters such as front, back tensions, speeds are taken into account but also rheological (fluid, solid) and tribological behaviours.

• Periodical: Advanced Materials Research (Volumes 966-967)
• Pages: 377-385
• DOI: https://doi.org/10.4028/www.scientific.net/AMR.966-967.377
• Online since: June 2014
• Authors: Raphael Deltombe*, Anastasia Belotserkovets, Laurent Dubar
• Keywords: Local Couette’s Equation, Lubrication, Metal Forming, Oil Trapping, Roughness

References

[1] J. A. Schey, Tribology in Metalworking: Friction, Lubrication and Wear, Asm Intl, Metals Park, Ohio, (1983).

[2] R. Ahmed, M. P. F. Sutcliffe, Identification of surface features on cold-rolled stainless steel strip, Wear 244 (1-2) (2000) 60–70.

DOI: 10.1016/s0043-1648(00)00442-7

[3] J. G. Lenard, Metal Forming Science and Practice: A State-of-the-Art Volume in Honour of Professor J.A. Schey's 80th Birthday, elsevier science, (2002).

[4] J. I. Bech, N. Bay, M. Eriksen, Entrapment and escape of liquid lubricant in metal forming, Wear 232 (2) (1999) 134–139.

DOI: 10.1016/s0043-1648(99)00136-2

[5] I. Shimizu, J. L. Andreasen, J. I. Bech, N. Bay, Influence of Workpiece Surface Topography on the Mechanisms of Liquid Lubrication in Strip Drawing, Journal of Tribology 123 (2) (2001) 290.

DOI: 10.1115/1.1308017

[6] C. Sorensen, B. J, J. Andreasen, N. Bay, U. Engel, T. Neudecker, A Basic Study of the Influence of Surface Topography on Mechanisms of Liquid Lubrication in Metal Forming, CIRP Annals - Manufacturing Technology 48 (1) (1999) 203–208.

DOI: 10.1016/s0007-8506(07)63166-7

[7] A. Wihlborg, Steel sheet surface topography and its influence on friction in a bending under tension friction test, International Journal of Machine Tools and Manufacture 41 (13-14) (2001) 1953–(1959).

DOI: 10.1016/s0890-6955(01)00060-8

[8] A. Stephany, J. P. Ponthot, Improvement of an Iterative and Staggered Approach for a Model of Mixed-Lubrication in Cold Rolling, AIP Conference Proceedings 712 (1) (2004) 406–411.

DOI: 10.1063/1.1766558

[9] M. P. F. Sutcliffe, H. R. Le, R. Ahmed, Modeling of Micro-Pit Evolution in Rolling or Strip-Drawing, Journal of Tribology 123 (4) (2001) 791.

DOI: 10.1115/1.1352741

[10] P. Montmitonnet, La plasto-hydrodynamique (PHD) application de la théeorie de la lubrification aux procédés de mise en forme des métaux, Comptes Rendus de l'Académie des Sciences - Series IV - Physics 2 (5) (2001) 729–737.

DOI: 10.1016/s1296-2147(01)01215-x

[11] M. Saniei, M. Salimi, Development of a mixed film lubrication model in cold rolling, Journal of Materials Processing Technology 177 (1-3) (2006) 575–581.

DOI: 10.1016/j.jmatprotec.2006.04.049

[12] H. Saito, M. Masuda, Modeling of blast process using indenting method, Precision engineering 28 (October 2003) (2004) 369–377.

DOI: 10.1016/j.precisioneng.2003.11.006

[13] E. d. S. Neto, P. D. Periæ, P. D. Owen, Computational Methods for Plasticity: Theory and Applications, Wiley, (2009).

[14] Abaqus, Theory Manual (2008).

[15] G. Stachowiak, A. Batchelor, Engineering tribology, Butterworth-Heinemann, (2005).

[16] A. K. Mohanty, Fluid Mechanics, PHI Learning Pvt. Ltd., (2004).

[17] S. Kucharski, G. Starzyski, A. Bartoszewicz, Prediction of surface roughness in metal forming with liquid lubricant, Tribology International 43 (1-2) (2010) 29–39.

DOI: 10.1016/j.triboint.2009.04.028

[18] S. Huart, M. Dubar, R. Deltombe, A. Dubois, L. Dubar, Asperity deformation, lubricant trapping and iron fines formation mechanism in cold rolling processes, Wear 257 (5-6) (2004) 471–480.

DOI: 10.1016/j.wear.2004.01.012

[19] X. Roizard, F. Raharijaona, Influence of sliding direction and sliding speed on the micro- hydrodynamic lubrication component of aluminium mill-finish sheets, Tribology International 32 (1999) (2000) 739–747.

DOI: 10.1016/s0301-679x(00)00008-6

[20] C. Hubert,N. Bay, P. Christiansen, R. Deltombe, L. Dubar, M. Dubar, and A Dubois. Numerical Simulation of Lubrication Mechanisms at Mesoscopic Scale. CIRP Annals - Manufacturing Technology 61 (2012) 271–274.

DOI: 10.1016/j.cirp.2012.03.126