|About this Abstract
||NUMIFORM 2019: The 13th International Conference on Numerical Methods in Industrial Forming Processes
||S-07: Computational Modelling of Scaled Processes and Experiments
||Multi-scale Friction Modeling of Coated Steels for Sheet Metal Forming Applications
||Meghshyam Prabhakar Shisode, Javad Hazrati, Tanmaya Mishra, Matthijn de Rooij, Ton van den Boogaard
|On-Site Speaker (Planned)
||Meghshyam Prabhakar Shisode
Accuracy of FE simulation of metal forming processes is usually hindered by in-exact modeling of coefficient of friction. Friction in sheet metal forming is a local phenomenon which depends on local contact pressure, surface topographies, material behavior and the lubrication condition. Nowadays, coated steels are widely used in the industry for better corrosion resistance. The coating can significantly affect the frictional behavior and hence the formability. Therefore, it is necessary to take the micro-mechanical behavior of the coating into account to understand its frictional behavior. In this study, a new multi-scale friction model for boundary lubrication regime is developed for coated sheet: material behavior and measured surface topologies of the coating and substrate are modeled explicitly. The real area of contact and furthermore the contact patches between the tool and the sheet is determined for different loading conditions. A newly developed flattening model for the coated sheet is used for this purpose. The coefficient of friction is determined based on the contribution of ploughing of tool asperities through the sheet material at contact patches and the shearing of boundary layer formed by the lubricant on the sheet. A single asperity micro-scale model, ploughing through the perfectly plastic material is adapted to macro-scale to determine the overall coefficient of friction. The friction model is validated relative to lab-scale friction tests on coated sheet samples with distinct surface textures. The current multi-scale model is coupled with industrial scale forming simulations to account for the local contact condition dependent friction coefficient.