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Evaluation of Coefficient of Friction and Investigation into the Effect of Friction and Lubrication on Formability of Ultra-thin Sheets

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Abstract

In this present work, the coefficient of friction (COF) at the interface of punch and ultra-thin sheet materials of AA1050, C101 and SS304 grades was evaluated under dry and lubricated conditions using a sub-sized stretch forming test setup and tribometer. The finite element (FE) models of the stretch forming process and stamping of serpentine shaped micro-channels were developed incorporating the experimentally evaluated COF and the anisotropic properties of all the three materials. It was found that the deformation load during the stretch forming process was influenced by the COF; however, the ratio of interface contact pressure to strength coefficient of the material at the inflection point was found to be negligible. The strain path during the stretch forming process shifted close to equi-biaxial deformation mode with more uniform strain distribution and delayed localized necking under the application of Teflon tape and lubricating oil. Moreover, the successful stamping of micro-channels on these ultra-thin sheets was demonstrated under both dry and lubricated conditions, and the effect of lubrication on the formability of the channel was presented in terms of peak load, maximum thinning and thickness distribution along the channel wall.

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  1. Department of Mechanical Engineering, Indian Institute of Technology, Kharagpur, West Bengal, 721302, India

    Coomar Sudarsan & Sushanta Kumar Panda

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  1. Coomar Sudarsan
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Sudarsan, C., Panda, S.K. Evaluation of Coefficient of Friction and Investigation into the Effect of Friction and Lubrication on Formability of Ultra-thin Sheets. J. of Materi Eng and Perform 32, 7737–7755 (2023). https://doi.org/10.1007/s11665-022-07689-1

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