Abstract
The application of surface texturing on sheet metal is a widely used approach to improve lubrication and control friction in deep drawing applications. However, it has been shown that current texturing processes are not robust to produce uniform textures on the sheet due to rapid and severe wear on texture-rolls. Furthermore, in multi-stage forming processes, deterioration of the sheet texture even at the first stage of forming makes texturing of the sheet metal surface ineffective. Tool surface texturing is a new method to control friction and tool wear in metal forming industry. In the current study, a multi-scale friction model is adopted to investigate the effect of tool texturing on the evolution of friction during sheet metal forming operations. The multi-scale friction model accounts for surface topography changes due to deformation of asperities and ploughing of tool asperities on the sheet metal surface, mixed lubrication regime and furthermore the tool micro-texture effects on lubricant distribution at tool-sheet metal interface. The model is validated with respect to strip-draw experiments using different tool textures. The model is later applied to the simulation of a U-bend forming process. The results show that using textured tools, it is possible to reduce friction and punch force in sheet metal forming processes. The model can be used to tailor and optimize textures on stamping tools for complex parts.
Highlights
Tool surface texturing is a new method to control friction and tool wear in metal forming industry
The goal of this paper is to investigate the effect of tool surface texture on its frictional behavior during forming of a sheet metal product
In the current study, a multi-scale friction model [14] is used to investigate the effect of tool surface texturing on the evolution of friction during strip draw test and U-bend forming application
Summary
In sheet metal forming processes, friction between the sheet and tools is a determining factor in the efficiency and quality of the process. Surface texturing is an attractive approach to enhance frictional behavior and load support of contacting surfaces [1] This method is successfully used in low load conditions such as bearings [2, 3] to reduce hydrodynamic friction where the contacting surfaces have low convergence ratio. In this method, shallow micro-pockets are incorporated deterministically or stochastically on one of the bearing surfaces using different methods such as laser beam machining, hammer peening, abrasive jet machining, electro-discharge machining, etc. These micro-pockets act as fluid reservoirs to retain a thin film of lubrication between contacting surfaces
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