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Open AccessArticle

Analysis of Sheet Metal Forming (Stamping Process): A Study of the Variable Friction Coefficient on 5052 Aluminum Alloy

by 1,2 and 2,*
1
College of Mechanical and Electrical Engineering, Nanjing University of Aeronautics and Astronautics, Nanjing 210016, China
2
School of Mechanical Engineering, Yancheng Institute of Technology, Yancheng 224051, China
*
Author to whom correspondence should be addressed.
Metals 2019, 9(8), 853; https://doi.org/10.3390/met9080853
Received: 2 July 2019 / Revised: 31 July 2019 / Accepted: 1 August 2019 / Published: 3 August 2019
(This article belongs to the Special Issue Computational Methods in Manufacturing Processes)
Under a boundary lubrication regime, the effect of sliding velocity and normal loads on the friction coefficient in the sheet metal stamping process was investigated using a pin-on-disk sliding wear test. Software was used to analyze both the data generated and the friction coefficient; in addition, a variable friction model based on different velocities and normal loads was also initiated. Under different experimental conditions and numerous influences, both the analysis and microtopography examination of sheet metal helped to obtain the mechanism influence on the friction coefficient. Through further analysis of the microtopography of sheet metal, the law of the surface roughness of sheet metal after grinding with stamping die was established. The model was established to simulate the thickness distribution and spring-back of U-bend parts using ABAQUS software. The results show that the friction coefficient values between the sheet metal and the stamping die generally decrease with increasing sliding velocity and normal loads, and the decreasing tendency slows down under a higher sliding velocity and normal load. Furrow wear and abrasive wear are the main wear mechanisms, with slight sticking wear under the boundary lubrication; the surface roughness after grinding with stamping die generally increases with increasing normal loads and decreasing sliding velocity. The predicted results of thickness distribution with a constant friction coefficient of 0.1 and with the variable friction coefficient model are more consistent with the actual measured values, but the predicted accuracy of spring-back in the variable friction coefficient model is higher than that of the constant friction coefficient model. View Full-Text
Keywords: sheet metal forming; sliding velocity; normal loads; friction coefficient; finite element simulation sheet metal forming; sliding velocity; normal loads; friction coefficient; finite element simulation
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Dou, S.; Xia, J. Analysis of Sheet Metal Forming (Stamping Process): A Study of the Variable Friction Coefficient on 5052 Aluminum Alloy. Metals 2019, 9, 853.

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Metals, EISSN 2075-4701, Published by MDPI AG
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