Friction modelling in sheet metal forming simulations: application and validation on an U-Bend product

Mats Sigvant, Johan Hol, Toni Chezan, Ton van den Boogaard

Research output: Chapter in Book/Report/Conference proceedingConference contributionAcademicpeer-review

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Abstract

The accuracy of sheet metal forming simulations strongly depends on, amongst others, friction modelling. The industrial standard is to use the Coulomb friction model with a constant coefficient of friction. However, it is known that the true friction conditions are dependent on the tribology system, i.e. the applied sheet material, coating and tooling material, the lubrication and process conditions. In this paper, an approach is presented for friction modelling in sheet metal forming simulations. The approach is applied to the forming of U-bend test parts for varying tribology systems as commonly used in the automotive indus-try. The friction conditions per system are described using a physically-based friction model included in the Triboform Software. Friction in the U-bend simulations are described as a function of local contact pressure, relative sliding velocity and straining in the sheet material. The simulation results are validated using U-bend forming experiments. It is concluded that the numerical prediction of the punch force magnitude is highly sensitive to friction. In addition to an overall improvement of the prediction accuracy of stamping simulations by including friction modelling, this approach enables to model friction and the effect of varying tribology systems on the final stamped part quality.
Original languageEnglish
Title of host publicationAdvanced constitutive models in sheet metal forming
EditorsP. Hora
Place of PublicationZurich
PublisherInstitute of Virtual Manufacturing
Pages135-142
ISBN (Print)978-3-906031-98-9
Publication statusPublished - 29 Jun 2015
Event8th Forming Technology Forum 2015: Advanced constitutive models in sheet metal forming - ETH Zurich, Zurich, Switzerland
Duration: 29 Jun 201530 Jun 2015

Conference

Conference8th Forming Technology Forum 2015
CountrySwitzerland
CityZurich
Period29/06/1530/06/15

Fingerprint

Metal forming
Sheet metal
Friction
Tribology
Stamping
Lubrication
Coatings

Keywords

  • IR-96303
  • METIS-310898

Cite this

Sigvant, M., Hol, J., Chezan, T., & van den Boogaard, T. (2015). Friction modelling in sheet metal forming simulations: application and validation on an U-Bend product. In P. Hora (Ed.), Advanced constitutive models in sheet metal forming (pp. 135-142). Zurich: Institute of Virtual Manufacturing.
Sigvant, Mats ; Hol, Johan ; Chezan, Toni ; van den Boogaard, Ton. / Friction modelling in sheet metal forming simulations: application and validation on an U-Bend product. Advanced constitutive models in sheet metal forming. editor / P. Hora. Zurich : Institute of Virtual Manufacturing, 2015. pp. 135-142
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abstract = "The accuracy of sheet metal forming simulations strongly depends on, amongst others, friction modelling. The industrial standard is to use the Coulomb friction model with a constant coefficient of friction. However, it is known that the true friction conditions are dependent on the tribology system, i.e. the applied sheet material, coating and tooling material, the lubrication and process conditions. In this paper, an approach is presented for friction modelling in sheet metal forming simulations. The approach is applied to the forming of U-bend test parts for varying tribology systems as commonly used in the automotive indus-try. The friction conditions per system are described using a physically-based friction model included in the Triboform Software. Friction in the U-bend simulations are described as a function of local contact pressure, relative sliding velocity and straining in the sheet material. The simulation results are validated using U-bend forming experiments. It is concluded that the numerical prediction of the punch force magnitude is highly sensitive to friction. In addition to an overall improvement of the prediction accuracy of stamping simulations by including friction modelling, this approach enables to model friction and the effect of varying tribology systems on the final stamped part quality.",
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Sigvant, M, Hol, J, Chezan, T & van den Boogaard, T 2015, Friction modelling in sheet metal forming simulations: application and validation on an U-Bend product. in P Hora (ed.), Advanced constitutive models in sheet metal forming. Institute of Virtual Manufacturing, Zurich, pp. 135-142, 8th Forming Technology Forum 2015, Zurich, Switzerland, 29/06/15.

Friction modelling in sheet metal forming simulations: application and validation on an U-Bend product. / Sigvant, Mats; Hol, Johan; Chezan, Toni; van den Boogaard, Ton.

Advanced constitutive models in sheet metal forming. ed. / P. Hora. Zurich : Institute of Virtual Manufacturing, 2015. p. 135-142.

Research output: Chapter in Book/Report/Conference proceedingConference contributionAcademicpeer-review

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N2 - The accuracy of sheet metal forming simulations strongly depends on, amongst others, friction modelling. The industrial standard is to use the Coulomb friction model with a constant coefficient of friction. However, it is known that the true friction conditions are dependent on the tribology system, i.e. the applied sheet material, coating and tooling material, the lubrication and process conditions. In this paper, an approach is presented for friction modelling in sheet metal forming simulations. The approach is applied to the forming of U-bend test parts for varying tribology systems as commonly used in the automotive indus-try. The friction conditions per system are described using a physically-based friction model included in the Triboform Software. Friction in the U-bend simulations are described as a function of local contact pressure, relative sliding velocity and straining in the sheet material. The simulation results are validated using U-bend forming experiments. It is concluded that the numerical prediction of the punch force magnitude is highly sensitive to friction. In addition to an overall improvement of the prediction accuracy of stamping simulations by including friction modelling, this approach enables to model friction and the effect of varying tribology systems on the final stamped part quality.

AB - The accuracy of sheet metal forming simulations strongly depends on, amongst others, friction modelling. The industrial standard is to use the Coulomb friction model with a constant coefficient of friction. However, it is known that the true friction conditions are dependent on the tribology system, i.e. the applied sheet material, coating and tooling material, the lubrication and process conditions. In this paper, an approach is presented for friction modelling in sheet metal forming simulations. The approach is applied to the forming of U-bend test parts for varying tribology systems as commonly used in the automotive indus-try. The friction conditions per system are described using a physically-based friction model included in the Triboform Software. Friction in the U-bend simulations are described as a function of local contact pressure, relative sliding velocity and straining in the sheet material. The simulation results are validated using U-bend forming experiments. It is concluded that the numerical prediction of the punch force magnitude is highly sensitive to friction. In addition to an overall improvement of the prediction accuracy of stamping simulations by including friction modelling, this approach enables to model friction and the effect of varying tribology systems on the final stamped part quality.

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Sigvant M, Hol J, Chezan T, van den Boogaard T. Friction modelling in sheet metal forming simulations: application and validation on an U-Bend product. In Hora P, editor, Advanced constitutive models in sheet metal forming. Zurich: Institute of Virtual Manufacturing. 2015. p. 135-142