Multi-scale contact modeling of coated steels for sheet metal forming applications

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    1 Citation (Scopus)

    Abstract

    Friction in sheet metal forming is a local phenomenon which depends on continuously evolving contact conditions during the forming process. This is mainly influenced by local contact pressure, surface textures of the sheet metal as well as the forming tool surface profile and material behavior. The first step for an accurate prediction of friction is to reliably estimate real area of contact at various normal loads. In this study, a multi-scale contact model for the normal load is presented to predict asperity deformation in coated steels and thus to estimate the real area of contact. Surface profiles of the zinc layer and steel substrate are modelled explicitly obtained from confocal measurements. Different mechanical properties are assigned to the zinc coating and the steel substrate. The model was calibrated and validated relative to lab-scale normal load tests using different samples of zinc coated steel with distinct surface textures. The results show that the model is able to predict the real area of contact in zinc-coated steels for various contact pressures and different surface textures. Current multi-scale model can be used to determine the local friction coefficient in sheet metal forming processes more accurately.

    Original languageEnglish
    Title of host publicationTribology in Manufacturing Processes and Joining by Plastic Deformation II
    EditorsNiels Bay, Chris V. Nielsen
    PublisherTrans Tech Publications Ltd
    Pages223-231
    Number of pages9
    ISBN (Print)9783035712995
    DOIs
    Publication statusPublished - 2018
    Event8th International Conference on Tribology in Manufacturing Processes & Joining by Plastic Deformation, ICTMP 2018 - Helsingør, Denmark
    Duration: 24 Jun 201826 Jun 2018
    Conference number: 8
    http://www.conferencemanager.dk/ICTMP2018

    Publication series

    NameKey Engineering Materials
    PublisherScientific.net
    Volume767
    ISSN (Print)1013-9826

    Conference

    Conference8th International Conference on Tribology in Manufacturing Processes & Joining by Plastic Deformation, ICTMP 2018
    Abbreviated titleICTMP
    CountryDenmark
    CityHelsingør
    Period24/06/1826/06/18
    Internet address

    Keywords

    • Multi-scale contact model
    • Real area of contact
    • Sheet metal forming
    • Zinc coating

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  • Cite this

    Shisode, M., Hazrati Marangalou, J., Mishra, T., De Rooij, M., & Van Den Boogaard, T. (2018). Multi-scale contact modeling of coated steels for sheet metal forming applications. In N. Bay, & C. V. Nielsen (Eds.), Tribology in Manufacturing Processes and Joining by Plastic Deformation II (pp. 223-231). (Key Engineering Materials; Vol. 767). Trans Tech Publications Ltd. https://doi.org/10.4028/www.scientific.net/KEM.767.223