The application of surface texturing on sheet metal is a widely used approach to improve lubrication and control friction in deep drawing applications. However, it has been shown that current texturing processes are not robust to produce uniform textures on the sheet due to rapid and severe wear on texture-rolls. Furthermore, in multi-stage forming processes, deterioration of the sheet texture even at the first stage of forming makes texturing of the sheet metal surface ineffective. Tool surface texturing is a new method to control friction and tool wear in metal forming industry. In the current study, a multi-scale friction model is adopted to investigate the effect of tool texturing on the evolution of friction during sheet metal forming operations. The multi-scale friction model accounts for surface topography changes due to deformation of asperities and ploughing of tool asperities on the sheet metal surface, mixed lubrication regime and furthermore the tool micro-texture effects on lubricant distribution at tool-sheet metal interface. The model is validated with respect to strip-draw experiments using different tool textures. The model is later applied to the simulation of a U-bend forming process. The results show that using textured tools, it is possible to reduce friction and punch force in sheet metal forming processes. The model can be used to tailor and optimize textures on stamping tools for complex parts.
|Journal||IOP Conference Series: Materials Science and Engineering|
|Publication status||Published - 21 Sep 2018|
|Event||37th International Deep Drawing Research Group Conference 2018: Forming of High Performance Sheet Materials and Components - Kitchener, Canada|
Duration: 3 Jun 2018 → 7 Jun 2018
Conference number: 37