Determination of Actual Friction Factors in Metal Forming under Heavy Loaded Regimes Combining Experimental and Numerical Analysis
Abstract
:1. Introduction
2. Materials and Methods
2.1. Approach
- Experimental determination of the plastic flow curve for the material UNS A96082 used in the RCTs.
- Finite Element modelling to simulate RCTs, considering the flow curve previously obtained.
- Experimental performance of RCTs according to the alternative procedure presented in this paper. This procedure is based on the application of lubricant only at the beginning of the first stage during the compression of the rings and not at intermediate stages as usual in typical RCTs.
- Graphical representation of the dual friction factor map, which includes both the friction curves obtained by experiments in laboratory and by numerical simulations.
- Selection of the friction factor according to the deformation stage.
2.2. Determination of the Plastic Flow Curve
2.3. Lubricants
2.4. Finite Element Model
- Object description: all data associated with an object, including geometry, mesh, temperature, material, etc.
- Material data: data describing the behavior of the material under the conditions which it will reasonably experience during deformation.
- Inter object conditions: describes how the objects interact with each other, including contact and friction between objects.
- Simulation controls: definition of parameters such as discrete time steps to model the process.
- : effective flow stress,
- : effective plastic strain,
- : effective strain rate,
- : work temperature
- n: number of steps,
- x: total movement of the primary die,
- V: primary die velocity,
- Δt: is the time increment per step
2.5. Experimental Procedure
2.6. Finite Element Model Validation
3. Results and Discussion
3.1. Determination of Dimensional Variables
3.2. Dual Friction Factor Map
4. Conclusions
- For small deformation stages (rh < 20% in this work), the conventional RCT [10] can be applied, as the tribological conditions will remain similar during the operation (Table 3). Particularly, in this paper, friction factors obtained for small reductions were 0.12, 0.20, 0.23, and 0.24 for lubricants MoS2, aluminum anti-size, copper paste, and silicone oil, respectively.
- For large deformations-reductions (rh > 20% in this work), it would be advisable to use the alternative approach of the RCT presented in this paper (without any lubrication between steps), and to obtain an average value of the friction factor assigned to every lubricant-component pair in the range of deformation considered (Table 3). This average value was 0.18, 0.24, 0.25, and 0.32 for lubricants MoS2, aluminum anti-size, copper paste, and silicone oil, respectively. Some differences were also observed in the width of the range obtained for each lubricant, being small for aluminum anti-size and copper paste (0.08 and 0.04, respectively) and bigger for MoS2 and silicone oil (0.12 and 0.15, respectively). In these last two cases the determination of an average value is more critical.
Acknowledgments
Author Contributions
Conflicts of Interest
References
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Temperature (°C) | Ram Velocity (mm/min) | 1st Stage Load (kN) | 2nd Stage Load (kN) | 3rd Stage Load (kN) |
---|---|---|---|---|
20 | 2.5 | 30 | 50 | 70 |
Lubricants | Forming Stage | Inner Diameter (mm) | Outer Diameter (mm) |
---|---|---|---|
Aluminum anti-size | 1 | 5.149 | 10.989 |
2 | 4.803 | 12.510 | |
3 | 4.294 | 13.680 | |
MoS2 grease | 1 | 5.259 | 11.080 |
2 | 4.878 | 12.754 | |
3 | 4.476 | 13.735 | |
Silicone oil | 1 | 5.093 | 10.842 |
2 | 4.638 | 12.383 | |
3 | 4.002 | 12.982 | |
Copper paste | 1 | 5.102 | 10.943 |
2 | 4.800 | 12.538 | |
3 | 4.377 | 13.598 |
Friction Factor (m) | MoS2 Grease | Aluminum Anti-Size | Copper Paste | Silicone Oil |
---|---|---|---|---|
Small height reduction (rh < 20%) | 0.12 | 0.20 | 0.23 | 0.24 |
Large height reduction (rh > 20%) * | 0.12 < m < 0.24, mavg = 0.18 | 0.20 < m < 0.28, mavg = 0.24 | 0.23 < m < 0.27, mavg = 0.25 | 0.24 < m < 0.39, mavg = 0.32 |
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Camacho, A.M.; Veganzones, M.; Claver, J.; Martín, F.; Sevilla, L.; Sebastián, M.Á. Determination of Actual Friction Factors in Metal Forming under Heavy Loaded Regimes Combining Experimental and Numerical Analysis. Materials 2016, 9, 751. https://doi.org/10.3390/ma9090751
Camacho AM, Veganzones M, Claver J, Martín F, Sevilla L, Sebastián MÁ. Determination of Actual Friction Factors in Metal Forming under Heavy Loaded Regimes Combining Experimental and Numerical Analysis. Materials. 2016; 9(9):751. https://doi.org/10.3390/ma9090751
Chicago/Turabian StyleCamacho, Ana María, Mariano Veganzones, Juan Claver, Francisco Martín, Lorenzo Sevilla, and Miguel Ángel Sebastián. 2016. "Determination of Actual Friction Factors in Metal Forming under Heavy Loaded Regimes Combining Experimental and Numerical Analysis" Materials 9, no. 9: 751. https://doi.org/10.3390/ma9090751
APA StyleCamacho, A. M., Veganzones, M., Claver, J., Martín, F., Sevilla, L., & Sebastián, M. Á. (2016). Determination of Actual Friction Factors in Metal Forming under Heavy Loaded Regimes Combining Experimental and Numerical Analysis. Materials, 9(9), 751. https://doi.org/10.3390/ma9090751