Pressure and sliding velocity dependent surface asperity based friction model: Application to springback simulation

Abstract

For accurate predictions of the formability and springback in the finite element sheet forming simulations, significant advances have been achieved in constitutive modeling that captures complex deformations occurring in the sheet forming process. However, friction behavior has been still modeled and implemented as a simple way though it is one of critical factors for accurate numerical simulations. For instance, sheet metal forming simulations often employ the Coulomb friction law with a constant friction coefficient, but it is known to be a function of other factors such as contact pressure, sliding rate and other surface quality. In this study, the microscopic surface asperity based friction model originally proposed by Westeneng [1], as one of microscale level friction models, was revisited by using additional contact assumptions. In particular, the model added the strain rate effect to the existing contact pressure dependent model in order to include the effect of both contact pressure and sliding velocity during sheet forming process. The calculated contact friction coefficient was compared to that by the measured for dual-phase 780 steel sheet under different pressure and sliding velocity. Moreover, the predicted friction model was employed in the simulation of U-draw bending springback by using a user friction subroutine, which was evaluated by the comparison of experimentally measured springback profile