Investigation on Friction Conditions during a Severe Bending Deformation on a Thick Plate

Abstract:

In this paper, the friction behaviour in a severe bending process of a thick plate was investigated, taking into account both dry and lubricated conditions. Early experimental tests were performed to obtain mechanical properties of the low carbon steel AISI 1006, to be used as input in FE solver. Besides a 3D thermo-mechanical model based on FEM was developed to predict stress and strain distributions and final component dimensions. The second experimental series was composed of a coining process and a forming operation to reach the size of the final part. The analysis and the control of the friction conditions has permitted to obtain a product of higher quality that permitted to avoid all the secondary machining operations previously required.

• Periodical: Key Engineering Materials (Volume 716)
• Pages: 176-183
• DOI: https://doi.org/10.4028/www.scientific.net/KEM.716.176
• Online since: October 2016
• Authors: A. D'Annibale*, Mohamad El Mehtedi, Antoniomaria Di Ilio, Filippo Gabrielli, Lorenzo Panaccio
• Keywords: Finite Element Method (FEM), Friction Conditions, Severe Bending, Sheet Bulk Metal Forming

References

[1] A. Forcellese, F. Gabrielli, A. Barcellona, F. Micari. Evaluation of friction in cold metal forming, J. Mater. Process. Tech. 45 (1994) 619-624.

DOI: 10.1016/0924-0136(94)90408-1

[2] J. Kondratiuk, P. Kuhn. Tribological investigation on friction and wear behaviour of coatings for hot sheet metal forming, Wear 270 (2011) 839-849.

DOI: 10.1016/j.wear.2011.02.011

[3] G. Sutter, G. List, J. Arnoux, A. Rusinek. Finite element simulation for analysing experimental friction tests under severe conditions, Finite Elem. Anal. Des. 85 (2014) 50-58.

DOI: 10.1016/j.finel.2014.03.007

[4] H.U. Vierzigmann, M. Merklein, U. Engel. Friction Conditions in Sheet-Bulk Metal Forming, Procedia Engineer 19 (2011).

DOI: 10.1016/j.proeng.2011.11.128

[5] K.H. Jung, H.C. Lee, D.K. Kim, S.H. Kang, Y.T. Im. Friction measurement by the tip test for cold forging, Wear 286 (2012) 19-26.

DOI: 10.1016/j.wear.2011.05.031

[6] Y.Z. Wang, P. Cavaliere, S. Spigarelli, E. Evangelista. Temperature and strain-rate sensitivity parameters: Analysis of the deformed metal matrix composite A359/SiC/20p, J. Mater. Sci. Lett. 20 (2001) 1195-1197.

[7] S.H. Kang, K.S. Lee, Y.S. Lee. Evaluation of interfacial friction condition by boss and rib test based on backward extrusion, Int. J. Mech. Sci. 53 (2011) 59-64.

DOI: 10.1016/j.ijmecsci.2010.11.001

[8] C. Becker, P. Hora, J. Maier, S. Muller. Experimental investigations of friction carried out with the Tribo-Torsion-Test and frictional modelling, Advances in Hot Metal Extrusion and Simulation of Light Alloys 585 (2014) 25-32.

DOI: 10.4028/www.scientific.net/kem.585.25

[9] X. Ma, M.B. de Rooij, D.J. Schipper. Friction conditions in the bearing area of an aluminium extrusion process, Wear 278 (2012) 1-8.

DOI: 10.1016/j.wear.2011.11.001

[10] H.Y. Lee, J.H. Noh, B.B. Hwang. Surface stresses and flow modes on contact surface in a combined double cup extrusion process, Tribol. Int. 64 (2013) 215-224.

DOI: 10.1016/j.triboint.2013.03.018

[11] M. Sawamura, Y. Yogo, M. Kamiyama, N. Iwata. Measurement of friction coefficient by backward extrusion with rotating tool under severe forming conditions, 11th International Conference on Technology of Plasticity, Ictp 2014 81 (2014) 1866-1871.

DOI: 10.1016/j.proeng.2014.10.247

[12] R. Matsumoto, K. Hayashi, H. Utsunomiya. Identification of friction coefficient in high aspect ratio combined forward-backward extrusion with pulse ram motion on servo press, 11th International Conference on Technology of Plasticity, Ictp 2014 81 (2014).

DOI: 10.1016/j.proeng.2014.10.245

[13] V. Shatermashhadi, B. Manafi, K. Abrinia, G. Faraji, M. Sanei. Development of a novel method for the backward extrusion, Mater. Design 62 (2014) 361-366.

DOI: 10.1016/j.matdes.2014.05.022