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HomeMaterials Science ForumMaterials Science Forum Vol. 1184Multiscale Simulation of Asperity Flattening with...

Multiscale Simulation of Asperity Flattening with Realistic Surface Topography and Microstructure

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Abstract:

In metal forming, the flattening of asperities on the workpiece surface is important to understand both for the impact it has on the properties of finished parts and the influence that real contact area has on tribological conditions during forming. The current study presents a method for the numerical modeling of asperity flattening of a deep drawing steel under high normal loads and no subsurface strain. At the microscale, a crystal plasticity model is employed to capture the propensity of grains to deform differently depending on their orientation. The continuum scale model is used to provide the boundary conditions to the microscale. The mechanical and microstructural properties of a DC04 deep drawing steel are used to provide the necessary parameters for the continuum and microscale models. The initial surface topography of the experimental material is measured by confocal microscopy and is mimicked in the input to the simulations. Surface topography measurements after flattening the experimental surface are used as validation for the simulated results, with real contact area, mean surface roughness, and autocorrelation length used as the primary figures of merit.

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Friction and Wear in Metal Forming

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Periodical:

Materials Science Forum (Volume 1184)

Pages:

21-33

DOI:

https://doi.org/10.4028/p-9iISdK

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Cite this paper

Online since:

April 2026

Authors:

Aiden Carley-Clopton*, Grethe Winther, Javad Hazrati, Chris Valentin Nielsen

Keywords:

Asperity Flattening, Crystal Plasticity, Multiscale Simulation

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* - Corresponding Author

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