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

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

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
Volume767 KEM
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
Volume767 KEM
ISSN (Print)10139826

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

Fingerprint

Steel
Metal forming
Sheet metal
Zinc
Textures
Friction
Zinc coatings
Substrates
Mechanical properties

Keywords

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

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 (Vol. 767 KEM, pp. 223-231). (Key Engineering Materials; Vol. 767 KEM). Trans Tech Publications Ltd. https://doi.org/10.4028/www.scientific.net/KEM.767.223
Shisode, Meghshyam ; Hazrati Marangalou, Javad ; Mishra, Tanmaya ; De Rooij, Matthijn ; Van Den Boogaard, Ton. / Multi-scale contact modeling of coated steels for sheet metal forming applications. Tribology in Manufacturing Processes and Joining by Plastic Deformation II. editor / Niels Bay ; Chris V. Nielsen. Vol. 767 KEM Trans Tech Publications Ltd, 2018. pp. 223-231 (Key Engineering Materials).
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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.",
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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 & CV Nielsen (eds), Tribology in Manufacturing Processes and Joining by Plastic Deformation II. vol. 767 KEM, Key Engineering Materials, vol. 767 KEM, Trans Tech Publications Ltd, pp. 223-231, 8th International Conference on Tribology in Manufacturing Processes & Joining by Plastic Deformation, ICTMP 2018, Helsingør, Denmark, 24/06/18. https://doi.org/10.4028/www.scientific.net/KEM.767.223

Multi-scale contact modeling of coated steels for sheet metal forming applications. / Shisode, Meghshyam; Hazrati Marangalou, Javad ; Mishra, Tanmaya; De Rooij, Matthijn; Van Den Boogaard, Ton.

Tribology in Manufacturing Processes and Joining by Plastic Deformation II. ed. / Niels Bay; Chris V. Nielsen. Vol. 767 KEM Trans Tech Publications Ltd, 2018. p. 223-231 (Key Engineering Materials; Vol. 767 KEM).

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

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N2 - 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.

AB - 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.

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