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A study on variable friction model in cold forging process with zinc phosphate coating

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Abstract

Friction has always been an urgent problem in metal forming process. Considering the coefficient of friction as a constant in the cold forging process tends to predict a larger stress–strain, this will lead to an inaccurate prediction result. This study takes AISI-1025 carbon steel with zinc phosphate coating as the research object, and a combination of finite element simulations and experiments is used to develope a pressure-dependent variable friction model. On the one hand, as the interface pressure is less than the critical pressure, it is still at a low friction level, and the friction factor can be measured by the sliding friction test; on the other hand, the friction factor is logarithmically increased with the interfacial pressure because of the rupture of the zinc phosphate coating. The variable friction model is then programmed into the finite element software as a subroutine and used to simulate the solid boss extrusion experiment. The predicted results are compared with the pressure-dependent variable friction model, the constant friction model, and the experimental validation results, which demonstrate that the variable friction model has a good prediction of deformation characteristic in cold forging process.

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Funding

This work is supported by financial support from the National Natural Science Foundation of China (No. 52275386), the Natural Science Foundation of Hunan Province (No. 2022JJ30565), and the Scientific Research Project of Hunan Provincial Department of Education (No. 21B0104).

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Authors and Affiliations

  1. School of Mechanical Engineering and Mechanics, Xiangtan University, Xiangtan, 411105, China

    Wenzheng Dong, Aoyu Zhao, Hui Tong & Qiquan Lin

  2. Department of Mechanical Engineering, Gifu University, Gifu, 501-1193, Japan

    Wenzheng Dong & Zhigang Wang

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  1. Wenzheng Dong
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Correspondence to Wenzheng Dong.

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Dong, W., Zhao, A., Tong, H. et al. A study on variable friction model in cold forging process with zinc phosphate coating. Int J Adv Manuf Technol 124, 3439–3451 (2023). https://doi.org/10.1007/s00170-022-10725-y

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  • DOI: https://doi.org/10.1007/s00170-022-10725-y

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