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FE-analysis and in situ visualization of pressure-, slip-rate-, and temperature-dependent coefficients of friction for advanced sheet metal forming: development of a novel coupled user subroutine for shell and continuum discretization

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Abstract

In sheet metal forming simulations using finite element method, the coefficient of friction according to Coulomb is normally assumed to be constant for the whole tool region. Recent research has demonstrated that under contact conditions typical for sheet metal forming, the coefficient of friction is strongly dependent on the contact pressure and the slip-rate between the interacting partners as well as on the contact temperature. A friction law based on the approach of Filzek is proposed in this research paper and implemented as a user subroutine in Abaqus. Moreover, a novel user subroutine coupling is developed which enables the visualization of local coefficients of friction for every contact node. For the very first time, this enables the in situ visualization of local coefficients of friction in sheet metal forming simulations using the FE system Abaqus. Multiple evaluation algorithms are presented as well. The presented friction model and the user subroutine coupling are validated using experimental data of an industrial deep drawing process. The proposed combination of the friction modeling and the in situ visualization of coefficients of friction enables the identification of friction hot spots. Based on such analysis, the tool and die making industry can realize tribologically optimized tools either by applying special coatings in areas of low or high friction, or by choosing different materials for tooling inserts, or by changing the type as well as the amount of the lubricant. Whereas the presented friction model is tailored to sheet metal forming and developed using the commercial code of Abaqus, the visualization coupling methodology is transferable to any manufacturing process and various FE systems supporting Fortran programming language.

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Authors and Affiliations

  1. Forming Technology, Laboratory for Machine Tools and Production Engineering (WZL) of RWTH Aachen University, Steinbachstr. 19, 52074, Aachen, Germany

    F. Klocke, D. Trauth, A. Shirobokov & P. Mattfeld

Authors
  1. F. Klocke
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  2. D. Trauth
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  3. A. Shirobokov
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  4. P. Mattfeld
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Correspondence to D. Trauth.

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Klocke, F., Trauth, D., Shirobokov, A. et al. FE-analysis and in situ visualization of pressure-, slip-rate-, and temperature-dependent coefficients of friction for advanced sheet metal forming: development of a novel coupled user subroutine for shell and continuum discretization. Int J Adv Manuf Technol 81, 397–410 (2015). https://doi.org/10.1007/s00170-015-7184-1

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  • DOI: https://doi.org/10.1007/s00170-015-7184-1

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