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Constitutive Friction Law for the Description and Optimization of Tailored Surfaces

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Sheet Bulk Metal Forming (TCRC73 2020)

Part of the book series: Lecture Notes in Production Engineering ((LNPE))

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Abstract

Due to the local application of bulk forming operations to sheet metal, often in combination with sheet metal forming, the tribology of sheet-bulk metal forming (SBMF) is characterised by more widely varying tribological loads than in conventional forming. Local loads, which are characteristic for bulk forming or sheet metal forming, occur. This complicates the numerical modelling of SBMF processes. Consequently, a half-space model is investigated that simulates the workpiece-tool contact under varying loads. A central challenge of SBMF is the limited geometrical accuracy of components because of a partly imperfect material flow. Hence, the potential of tailored tribological systems for material flow control by local adaptation of friction is investigated. It is numerically and experimentally shown that the material flow in SBMF can be controlled by local adaption of friction, thus improving the component accuracy regarding the die filling significantly. By using the half-space model, the functional relations of adaptions of tool- and workpiece surface were investigated and suitable tailored tribological systems are experimentally applied in SBMF processes. This shows that tailored friction systems have the potential to extend process limits through a material flow control in SBMF.

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Acknowledgement

This project was supported by the German Research Foundation (DFG) within the scope of the Transregional Collaborative Research Centre 73 for sheet-bulk metal forming (TCRC 73, Subproject C1) under grant number TRR73/3 68237143. The authors are also grateful to all laboratory assistants and students who supported the execution of this work.

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Authors and Affiliations

  1. Institute of Manufacturing Technology, Egerlandstraße 13, 91058, Erlangen, Germany

    Johannes Henneberg, Maria Löffler & Marion Merklein

  2. Chair of Applied Mechanics, Egerlandstraße 5, 91058, Erlangen, Germany

    Florian Beyer & Kai Willner

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  1. Johannes Henneberg
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  2. Florian Beyer
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  3. Maria Löffler
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  4. Kai Willner
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  5. Marion Merklein
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Correspondence to Johannes Henneberg .

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Editors and Affiliations

  1. Lehrstuhl für Fertigungstechnologie, Friedrich-Alexander-Universität, Erlangen, Bayern, Germany

    Marion Merklein

  2. Institut für Umformtechnik & Leichtbau, Technische Universität Dortmund, Dortmund, Nordrhein-Westfalen, Germany

    A. Erman Tekkaya

  3. Institut für Umformtechnik und Umformmaschinen, Leibniz Universität Hannover, Garbsen, Niedersachsen, Germany

    Bernd-Arno Behrens

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Henneberg, J., Beyer, F., Löffler, M., Willner, K., Merklein, M. (2021). Constitutive Friction Law for the Description and Optimization of Tailored Surfaces. In: Merklein, M., Tekkaya, A.E., Behrens, BA. (eds) Sheet Bulk Metal Forming . TCRC73 2020. Lecture Notes in Production Engineering. Springer, Cham. https://doi.org/10.1007/978-3-030-61902-2_14

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  • DOI: https://doi.org/10.1007/978-3-030-61902-2_14

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