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Advanced friction modeling for bulk metal forming processes

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Abstract

The finite element method is a powerful tool for the design and optimization of hot forming processes. In order to obtain high accuracy in simulation results, exact knowledge of the process conditions is required. Due to the fact that friction in the contact area has a significant impact on the material flow during the forming process, a realistic description of this boundary condition in the FE simulation is important for the usability of the simulation results. The most important influencing factors are the contact pressure, the roughness of the contact surfaces, the sliding velocity and the flow behavior of the material. Currently, only constant friction coefficients are considered in commercial finite element systems for the simulation of bulk metal forming processes. However, this description does not represent the state of the art in tribology. A new friction model is developed, taking into account the sliding velocity between tools and workpiece. This is confirmed by experimental and numerical investigations on model experiments and industrial process.

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Acknowledgments

The authors would like to thank the Institute of Metal Forming (IBF) of the RWTH Aachen University for the experiments of the bulge process with the newly designed die and the data acquisition of the forming forces. Our special thanks are due to the Hirschvogel Automotive Group for providing an industrial forging process. The authors would also like to thank the Simufact Engineering GmbH for the implementation of the new friction model. Moreover, the authors are much obliged to the German Federation of Industrial Research Associations (AiF), the Research Association of Steel Forming (FSV) and the Research Association for Steel Application (FOSTA) for funding the research project P772 AiF IGF 15204 N “Investigation and extension of existing approaches to the improved description of friction and heat transfer in the FEM simulation of hot forming processes”.

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Authors and Affiliations

  1. Institute of Metal Forming and Metal-Forming Machines (IFUM), Leibniz Universität Hannover, An der Universität 2, 30823, Garbsen, Germany

    Bernd-Arno Behrens, Anas Bouguecha, Tarik Hadifi & Jens Mielke

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  1. Bernd-Arno Behrens
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  2. Anas Bouguecha
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  3. Tarik Hadifi
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  4. Jens Mielke
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Correspondence to Jens Mielke.

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Behrens, BA., Bouguecha, A., Hadifi, T. et al. Advanced friction modeling for bulk metal forming processes. Prod. Eng. Res. Devel. 5, 621–627 (2011). https://doi.org/10.1007/s11740-011-0344-8

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  • DOI: https://doi.org/10.1007/s11740-011-0344-8

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