Abstract
Understanding asperity flattening is vital for a reliable macro-scale modeling of friction and wear. In sheet metal forming processes, sheet surface asperities are deformed due to contact forces between the tools and the workpiece. In addition, as the sheet metal is strained while retaining the normal load, the asperity deformation increases significantly. Deformation of the asperities determines the real area of contact which influences the friction and wear at the tool-sheet metal contact. The real area of contact between two contacting rough surfaces depends on type of loading, material behavior, and topography of the contacting surfaces. In this study, an experimental setup is developed to investigate the effect of a combined normal load and sub-surface strain on real area of contact. Uncoated and zinc coated steel sheets (GI) with different coating thicknesses, surface topographies, and substrate materials are used in the experimental study. Finite element (FE) analyses are performed on measured surface profiles to further analyze the behavior observed in the experiments and to understand the effect of surface topography, and coating thickness on the evolution of the real area of contact. Finally, an analytical model is presented to determine the real area contact under combined normal load and sub-surface strain. The results show that accounting for combined normal load and sub-surface straining effects is necessary for accurate predictions of the real area of contact.
Article PDF
Similar content being viewed by others
Avoid common mistakes on your manuscript.
References
Bay N, Wanheim T. Real area of contact and friction stress at high pressure sliding contact. Wear 38(2): 201–209 (1976)
Bay N. Friction stress and normal stress in bulk metal-forming processes. Journal of mechanical working technology 14(2): 203–223 (1987)
Wanheim T, Bay N, Petersen A. A theoretically determined model for friction in metal working processes. Wear 28(2): 251–258 (1974)
Chang W R, Etsion I, Bogy D. B. An elastic-plastic model for the contact of rough surfaces. Journal of Tribology 109(2): 257–263 (1987)
Zhao Y, Maietta D M, Chang L. An asperity microcontact model incorporating the transition from elastic deformation to fully plastic flow. Journal of Tribology 122(1): 86–93 (2000)
Westeneng J D. Modelling of contact and friction in deep drawing processes. Ph.D Thesis. Netherlands (Twente): University of Twente, 2001.
Chen Z, Goltsberg R, Etsion I. A universal model for a frictionless elastic-plastic coated spherical normal contact with moderate to large coating thicknesses. Tribology International 114: 485–493 (2017)
Chang W R. An elastic-plastic contact model for a rough surface with an ion-plated soft metallic coating. Wear 212(2): 229–237 (1997)
Mulki H, Mizuno T. Contact mechanics of zinc-coated steel sheets. Wear 199(2): 260–267 (1996)
Shisode M, Hazrati J, Mishra T, de Rooij M, van den Boogaard T. Multi-scale contact modeling of coated steels for sheet metal forming applications. Key Engineering Materials 767: 223–231 (2018)
Shisode M, Hazrati J, Mishra T, de Rooij M, van den Boogaard A. Semi-analytical contact model to determine the attening behavior of coated sheets under normal load. Tribology International 106182 (2020).
Wichern C, De Cooman B, and Van Tyne C. Surface roughness of a hot-dipped galvanized sheet steel as a function of deformation mode. Journal of Materials Processing Technology 160(3): 278–288 (2005)
Wichern C, De Cooman B, Van Tyne C. Surface roughness changes on a hot-dipped galvanized sheet steel during deformation at low strain levels. Acta materialia 52(5): 1211–1222 (2004)
Wang Z, Yoshikawa Y, Suzuki T, Osakada K. Determination of friction law in dry metal forming with dlc coated tool. CIRP Annals 63(1): 277–280 (2014)
Nielsen C V, Martins P A, Bay N. Modelling of real area of contact between tool and workpiece in metal forming processes including the Influence of subsurface deformation. CIRP Annals 65(1): 261–264 (2016)
Sutcliffe M. Surface asperity deformation in metal forming processes. International Journal of Mechanical Sciences 30(11): 847–868 (1988)
Wilson W, Sheu S. Real area of contact and boundary friction in metal forming. International journal of mechanical sciences 30(7): 475–489 (1988)
Ike H, Makinouchi A. Effect of lateral tension and compression on plane strain flattening processes of surface asperities lying over a plastically deformable bulk. Wear, 140(1): 17–38 (1990)
Halling J, Arnell R. Ceramic coatings in the war on wear. Wear 100(1–3): 367–380 (1984)
Song G, Sloof W, Pei Y, De Hosson J T M. Interface fracture behavior of zinc coatings on steel: Experiments and finite element calculations. Surface and Coatings Technology 201(7): 4311–4316 (2006)
Pei Y T, Song G, Sloof W G, De Hosson J T M. A methodology to determine anisotropy effects in non-cubic coatings. Surface and Coatings Technology 201(16–17): 6911–6916 (2007)
Mishra T, de Rooij M, Shisode M, Hazrati J, Schipper D J. Characterization of interfacial shear strength and its effect on ploughing behaviour in single-asperity sliding. Wear 436: 203042 (2019)
Hol J. Multi-scale friction modeling for sheet metal forming. Ph.D Thesis. Netherlands (Twente): University of Twente, 2013.
Tabor D. The hardness of solids. Review of physics in technology 1(3): 145 (1970)
de Rooij M. Tribological aspects of unlubricated deep drawing processes. Ph.D Thesis. Netherlands (Twente): University of Twente, 1998.
Hol J, Meinders V T, de Rooij M B, van den Boogaard A H. Multi-scale friction modeling for sheet metal forming: The boundary lubrication regime. Tribology International 81: 112–128 (2015)
Acknowledgements
This research was carried out under project number S22.1.14520b in the framework of the Partnership Program of the Materials Innovation Institute M2i (www.m2i.nl) and the Technology Foundation TTW (www.stw.nl), which is part of the Netherlands Organization for Scientific Research (www.nwo.nl). The authors would like to greatly acknowledge Dr.ir. Jeroen van Beeck, Dr.ir. Carel ten Horn, Dr.ir. Matthijs Toose, and Marco Appelman from Tata Steel Europe for technical guidance and assistance during the experiments.
Author information
Authors and Affiliations
Corresponding author
Additional information
Meghshyam SHISODE. He received his bachelor degree in mechanical engineering from Savitribai Phule Pune University, India (formerly known as University of Pune) and master degree in mechanical engineering from Indian Institute of Science, Bangalore, India. Then he worked in General Electric (aviation) as a design engineer. Later, he earned his Ph.D. in 2020 from nonlinear solid mechanics research group at University of Twente, The Netherlands. His research interests include tribology, multi-scale friction modeling, and surface engineering.
Rights and permissions
Open Access This article is licensed under a Creative Commons Attribution 4.0 International License, which permits use, sharing, adaptation, distribution and reproduction in any medium or format, as long as you give appropriate credit to the original author(s) and the source, provide a link to the Creative Commons licence, and indicate if changes were made.
The images or other third party material in this article are included in the article’s Creative Commons licence, unless indicated otherwise in a credit line to the material. If material is not included in the article’s Creative Commons licence and your intended use is not permitted by statutory regulation or exceeds the permitted use, you will need to obtain permission directly from the copyright holder.
To view a copy of this licence, visit http://creativecommons.org/licenses/by/4.0/.
About this article
Cite this article
Shisode, M., Hazrati, J., Mishra, T. et al. Evolution of real area of contact due to combined normal load and sub-surface straining in sheet metal. Friction 9, 840–855 (2021). https://doi.org/10.1007/s40544-020-0444-6
Received:
Revised:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s40544-020-0444-6