Abstract
The quality of sheet metal formed parts is strongly dependent on the tribology and friction conditions that are acting in the actual forming process. This paper focuses on the tribology conditions during early try-out of dies for new car models. The motivation for the study is that the majority of the forming simulations at Volvo Cars are performed to secure the die try-out, i.e. solve as many problems as possible in forming simulations before the final design of the die and milling of the casting. In the current study, three closure parts for the new Volvo V60 model have been analysed with both Coulomb and TriboForm friction models. The simulation results from the different friction models are compared using thickness measurements of real parts, and 3D geometry scanning data of the parts. Results show the improved prediction capability of forming simulations when using the TriboForm friction model, demonstrating the ability to accurately describe try-out conditions in sheet metal forming simulations.
Highlights
The quality of sheet metal formed parts is strongly dependent on the tribology and friction conditions that are acting in the production process [1,2]
This paper presents a selection of results considering friction and lubrication modeling in stamping simulations of dies for the new Volvo V60, demonstrating the strong influence of tribology and friction conditions on predictions of draw-in and sheet thickness
In the majority of the comparisons between simulation and measured data made in the study, the simulation accuracy is higher using the TriboForm models than using a constant coefficient of friction
Summary
The quality of sheet metal formed parts is strongly dependent on the tribology and friction conditions that are acting in the production process [1,2]. These friction conditions are dependent on the utilized sheet material, tooling material and lubricant. The current industrial standard is to use a constant (Coulomb) coefficient of friction This limits the overall simulation accuracy as demonstrated in earlier work of the authors, both for a U-bend application [3] and the Volvo XC90 right rear door inner [4,5]
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