Abstract
Friction is one of the important factors in sheet metal forming. It greatly affects dynamic behaviors of metal sheets and stress and strain distributions in the metal sheets. In this study, deformation characteristics, stress–strain distribution, and change law of symmetrical parts in the process of deep drawing are analyzed using a new theoretical model based on the plastic flow law and partitioning the forming area. In the model, the least-square method is used to linearize the friction coefficient in nonlinear problems and reverse the calculation of friction coefficients to interpret the friction coefficient. To evaluate the model, the friction coefficient in sheet metal drawing of axis-symmetric deep drawing parts under various friction conditions was measured using a self-developed measuring system. The comparison between the experimental results and the calculation using the model shows a good agreement. The results show that the drawing force increases with the increase in punch depth; the friction coefficient decreases with the rise in punch depth. The friction coefficient obtained by fitting is relatively stable, and the average error is less than 3%. Using the friction coefficient model in finite element simulation analysis, it shows that the thickness and blank shape errors are less than 5%. The novel method studied in this paper shows great significance in support for theoretical research, numerical simulation research, and sheet metal stamping performance evaluation.
Highlights
Sheet metal forming by plastic processing requires fewer consumables, and has high productivity and low cost
Axisymmetric parts are often found in sheet metal forming, which is a kind of plastic processing
The friction coefficients in sheet metal forming of an axisymmetric deep drawing part were measured with different material parameters by self-developed measuring equipment and compared with the calculations using the model
Summary
Sheet metal forming by plastic processing requires fewer consumables, and has high productivity and low cost. Ma et al [6] established a roughness model in metal forming Their results showed that the contact-specific area increased with the increase in nominal pressure, and the relative sliding between die and plate could increase the contactspecific area. K. Dohda et al [11] developed a new nonlinear friction coefficient model, considering the effects of contact pressure, velocity, sliding length, and friction work. Dohda et al [11] developed a new nonlinear friction coefficient model, considering the effects of contact pressure, velocity, sliding length, and friction work It showed that the friction coefficient decreased with the increase in sliding length. The friction coefficients in sheet metal forming of an axisymmetric deep drawing part were measured with different material parameters by self-developed measuring equipment and compared with the calculations using the model. The friction model is verified using finite element simulations and the experimental results
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