Strain Induced Surface Change in Sheet Metal Forming: Numerical Prediction, Influence on Friction and Tool Wear
In sheet metal forming, free deformation of the sheet takes place frequently without contact with forming tools. The pre-straining resulting from the free deformation leads to a surface roughening of the sheet metal. It is assumed that the roughening has an influence on friction and wear behavior of...
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| Format: | Article |
| Language: | English |
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MDPI AG
2021-03-01
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| Series: | Journal of Manufacturing and Materials Processing |
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| Online Access: | https://www.mdpi.com/2504-4494/5/2/29 |
| _version_ | 1797539525445025792 |
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| author | Yutian Wu Viktor Recklin Peter Groche |
| author_facet | Yutian Wu Viktor Recklin Peter Groche |
| author_sort | Yutian Wu |
| collection | DOAJ |
| description | In sheet metal forming, free deformation of the sheet takes place frequently without contact with forming tools. The pre-straining resulting from the free deformation leads to a surface roughening of the sheet metal. It is assumed that the roughening has an influence on friction and wear behavior of the following forming process as well as the painting quality after the manufacturing. In this paper, a numerical prediction based on a polycrystalline model is first proposed to predict the effect of surface roughing based on the material data of the as-received state of the sheet metal. Different states of strain are analyzed and the numerical result is validated through experimental evaluation. Besides the numerical prediction, the friction behavior after pre-straining is evaluated in strip drawing tests and the coefficient of friction (COF) is calculated. For interpretation of the measured COF, the surface roughness after the friction test and the surface image are evaluated by a transparent toolset. It is shown that the surface transformation as a result of pre-straining has a negative influence on the lubricating effect of the sheet metal and degrades the friction behavior. Finally, the influence of the strain-induced surface roughening on wear is discussed based on wear testing in strip drawing test with draw bead geometry. |
| first_indexed | 2024-03-10T12:47:10Z |
| format | Article |
| id | doaj.art-2e569dac4261496982eeeb15264f8833 |
| institution | Directory Open Access Journal |
| issn | 2504-4494 |
| language | English |
| last_indexed | 2024-03-10T12:47:10Z |
| publishDate | 2021-03-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Journal of Manufacturing and Materials Processing |
| spelling | doaj.art-2e569dac4261496982eeeb15264f88332023-11-21T13:21:40ZengMDPI AGJournal of Manufacturing and Materials Processing2504-44942021-03-01522910.3390/jmmp5020029Strain Induced Surface Change in Sheet Metal Forming: Numerical Prediction, Influence on Friction and Tool WearYutian Wu0Viktor Recklin1Peter Groche2Institute for Production Engineering and Forming Machines, Technische Universität Darmstadt, Otto-Berndt-Str. 2, 64287 Darmstadt, GermanyInstitute for Production Engineering and Forming Machines, Technische Universität Darmstadt, Otto-Berndt-Str. 2, 64287 Darmstadt, GermanyInstitute for Production Engineering and Forming Machines, Technische Universität Darmstadt, Otto-Berndt-Str. 2, 64287 Darmstadt, GermanyIn sheet metal forming, free deformation of the sheet takes place frequently without contact with forming tools. The pre-straining resulting from the free deformation leads to a surface roughening of the sheet metal. It is assumed that the roughening has an influence on friction and wear behavior of the following forming process as well as the painting quality after the manufacturing. In this paper, a numerical prediction based on a polycrystalline model is first proposed to predict the effect of surface roughing based on the material data of the as-received state of the sheet metal. Different states of strain are analyzed and the numerical result is validated through experimental evaluation. Besides the numerical prediction, the friction behavior after pre-straining is evaluated in strip drawing tests and the coefficient of friction (COF) is calculated. For interpretation of the measured COF, the surface roughness after the friction test and the surface image are evaluated by a transparent toolset. It is shown that the surface transformation as a result of pre-straining has a negative influence on the lubricating effect of the sheet metal and degrades the friction behavior. Finally, the influence of the strain-induced surface roughening on wear is discussed based on wear testing in strip drawing test with draw bead geometry.https://www.mdpi.com/2504-4494/5/2/29strainfree deformationsurface rougheningFEM-simulationstrip drawing testwear |
| spellingShingle | Yutian Wu Viktor Recklin Peter Groche Strain Induced Surface Change in Sheet Metal Forming: Numerical Prediction, Influence on Friction and Tool Wear Journal of Manufacturing and Materials Processing strain free deformation surface roughening FEM-simulation strip drawing test wear |
| title | Strain Induced Surface Change in Sheet Metal Forming: Numerical Prediction, Influence on Friction and Tool Wear |
| title_full | Strain Induced Surface Change in Sheet Metal Forming: Numerical Prediction, Influence on Friction and Tool Wear |
| title_fullStr | Strain Induced Surface Change in Sheet Metal Forming: Numerical Prediction, Influence on Friction and Tool Wear |
| title_full_unstemmed | Strain Induced Surface Change in Sheet Metal Forming: Numerical Prediction, Influence on Friction and Tool Wear |
| title_short | Strain Induced Surface Change in Sheet Metal Forming: Numerical Prediction, Influence on Friction and Tool Wear |
| title_sort | strain induced surface change in sheet metal forming numerical prediction influence on friction and tool wear |
| topic | strain free deformation surface roughening FEM-simulation strip drawing test wear |
| url | https://www.mdpi.com/2504-4494/5/2/29 |
| work_keys_str_mv | AT yutianwu straininducedsurfacechangeinsheetmetalformingnumericalpredictioninfluenceonfrictionandtoolwear AT viktorrecklin straininducedsurfacechangeinsheetmetalformingnumericalpredictioninfluenceonfrictionandtoolwear AT petergroche straininducedsurfacechangeinsheetmetalformingnumericalpredictioninfluenceonfrictionandtoolwear |