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Towards Multi-Scale Friction Modelling for Bulk Sheet Metal Forming Applications

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Abstract:

Cold forging and sheet‑metal bulk forming operations typically involve severe deformation, high contact pressures, and substantial surface enlargement. As highlighted in previous studies, friction behavior under these extreme conditions is governed by temperature, contact pressure, sliding velocity, and changes in the real contact area due to surface expansion. This work presents a newly developed linear sliding tribotester designed to characterize the friction response of metal sheets subjected to sheet‑metal bulk forming conditions. The testing procedure consists of two stages. In the first stage, the sample is compressed to intentionally modify and enlarge the initial contact surface, with the degree of surface expansion controlled by the specimen geometry. In the second stage, once the surface has been altered, frictional contact is generated between the sample and a sliding table, enabling the measurement of normal and tangential forces. These force measurements are subsequently used to determine the mean coefficient of friction. The results obtained constitute the first dataset toward the development of a multi‑scale friction model for sheet‑metal bulk gear forging. This model aims to incorporate the effects of extreme contact pressures, asperity flattening, and lubricant-related hydrostatic and hydrodynamic mechanisms.

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Periodical:

Materials Science Forum (Volume 1184)

Pages:

113-121

DOI:

https://doi.org/10.4028/p-3JRLbf

Citation:

Cite this paper

Online since:

April 2026

Authors:

Aratz Barandiaran, Alaitz Zabala, David Abedul, Javad Hazrati, Lander Galdos*

Keywords:

Friction Modelling, Sheet Metal Forming, Tribology

Funder:

The publication of this article was funded by the Mondragon Goi Eskola Politeknikoa, J.M.A. S.Coop

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* - Corresponding Author

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