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Abstract
This article presents research results on the effect of sheet metal surface roughness, lubricant conditions and sample orientation on the value of friction coefficient in the drawbead region of sheet metal-forming processes. Aluminium alloys with different temper conditions were used as test materials. The experimental results have ascertained several relationships showing the effect of surface profile and lubrication on the value of the friction coefficient. Based on experimental measurements, it may be concluded that the sample orientation and the lubrication conditions are crucial variables influencing the value of the coefficient of friction. Furthermore, a numerical model of the drawbead has been created in Msc.MARC Mentat software, and several simulations have been performed to study the stress/strain state in stretched sample during drawbead simulator tests. Both isotropic and anisotropic material models were used in the simulations taking into account the sample orientation with respect to the rolling direction of the sheet.
Highlights
Deep drawing is a key manufacturing process for sheet metal products
The application of machine oil reduces the value of friction coefficient, but its intensity depends on the surface roughness of the rolls
Numerical simulations are based on the aforementioned friction test using material model that is described by isotropic and anisotropic yield criteria
Summary
Deep drawing is a key manufacturing process for sheet metal products. The quality of the products and the efficiency of the drawing process depend on several parameters. Friction regimes encountered during deep drawing in particular are known to be extremely complex [1] and [2]. This is as a result of the inherent factors, such as the contact pressure, sliding velocity, surface roughness at sheet metal and tool interface, material properties of the tool and the blank, and the properties of the lubrication. Few regions of the draw piece with different stress and strain states, local sliding velocity, contact pressure and friction conditions exist
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