Abstract
Due to the local application of bulk forming operations to sheet metal, often in combination with sheet metal forming, the tribology of sheet-bulk metal forming (SBMF) is characterised by more widely varying tribological loads than in conventional forming. Local loads, which are characteristic for bulk forming or sheet metal forming, occur. This complicates the numerical modelling of SBMF processes. Consequently, a half-space model is investigated that simulates the workpiece-tool contact under varying loads. A central challenge of SBMF is the limited geometrical accuracy of components because of a partly imperfect material flow. Hence, the potential of tailored tribological systems for material flow control by local adaptation of friction is investigated. It is numerically and experimentally shown that the material flow in SBMF can be controlled by local adaption of friction, thus improving the component accuracy regarding the die filling significantly. By using the half-space model, the functional relations of adaptions of tool- and workpiece surface were investigated and suitable tailored tribological systems are experimentally applied in SBMF processes. This shows that tailored friction systems have the potential to extend process limits through a material flow control in SBMF.
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