Refined Friction Modeling for Simple Upsetting

1997 ◽  
Vol 119 (4A) ◽  
pp. 563-570 ◽  
Author(s):  
Tze-Chi Hsu ◽  
Chung-Hung Lee
Keyword(s):  
Friction Stress ◽  
Normal Pressure ◽  
Friction Model ◽  
Lubricant Film ◽  
Asperity Contact ◽  
Friction Modeling ◽  
Lubrication Regimes ◽  
Mixed Lubrication Regime ◽  
Boundary Model ◽  
Semi Empirical

A refined model for friction in lubricated simple upsetting processes which takes account of the different lubrication regimes which may occur at the workpiece/tooling interface is developed. The refined friction model considers not only the full film situation but also the mixed and boundary lubrication condition. The load carrying capacity of the lubricant in the mixed lubrication regime is evaluated by using the average flow model to treat the influence of surface roughness on lubricant flow. The mechanics of asperity contact is governed by a semi-empirical boundary model in which the plastic deformation of the workpiece is considered. The lubricant film thickness is then determined by using a shooting method to ensure that the interface pressure is partially supported by the asperity contact and partially supported by the lubricant film. The refined friction model is then combined with a rigid-plasticity finite element code to analyze the simple upsetting processes. Numerical results using the coupled codes such as the distribution of the friction stress and normal pressure, the geometry and surface topography of the deformed workpiece are compared with previous numerical and experimental investigation under different lubrication conditions. The simulation results are in good agreement with the experimental data.

State and Rate Dependent Friction Laws for Modeling High-Speed Frictional Slip at Metal-on-Metal Interfaces

2006 ◽  
Vol 129 (1) ◽  
pp. 17-22 ◽  
Author(s):  
Hamid Ullah ◽  
M. A. Irfan ◽  
V. Prakash
Keyword(s):  
Shear Stress ◽  
Steady State ◽  
High Speed ◽  
Friction Stress ◽  
Normal Pressure ◽  
Friction Model ◽  
Friction Laws ◽  
Rate Dependent ◽  
Applied Shear Stress ◽  
Slip Event

In the present paper the applicability of state and rate dependent friction laws in describing the phenomena of high speed slip at metal-on-metal interfaces is investigated. For the purpose of model validation, results of plate-impact pressure-shear friction experiments were conducted by Irfan in 1998 and Irfan and Prakash in 2000 using a Ti6Al4V and Carpenter Hampden tool-steel tribo pair are employed. In these experiments high normal pressures (1-3GPa) and slip speeds of approximately 50m∕s were attained during the high-speed slip event. Moreover, these experiments were designed to investigate the evolution of friction stress in response to step changes in normal pressure and also in the applied shear stress during the high-speed slip event. A step drop in normal pressure is observed to result in an exponential decay of the friction stress to a new steady-state characteristic of the current normal pressure and the current slip velocity. A step drop in applied shear stress is observed to lead to an initial drop in friction stress, which later increases toward a new steady-state friction stress level. In response to the step drop in applied shear stress the slip velocity initially increases and then decreases to a new steady-state level consistent with the new friction stress level. A modified rate and state dependent friction model that employs both velocity and normal stress dependent state variables is used to simulate the experimental results. A good correlation is found between the experimental results and the predictions of the proposed state and rate dependent friction model.

“Internal Variables” Effects in Punch Friction Characterization

1998 ◽  
Vol 120 (3) ◽  
pp. 510-516
Author(s):  
Tze-Chi Hsu ◽  
Chi-Chia Liu
Keyword(s):  
Metal Forming ◽  
Initial Boundary ◽  
Friction Model ◽  
Internal Variables ◽  
Friction Modeling ◽  
Lubrication Regimes ◽  
Mixed Regime ◽  
Constant Friction ◽  
Tensile Strip ◽  
Friction Models

Despite the complexity and importance of friction, most current simulations of metal-forming processes use relatively simple friction models such as the Amontons-Coulomb constant friction coefficient. It has been pointed out that simple models are not capable of capturing the influence of process variables such as geometry, speed, and surface topography on friction. A realistic friction model should include the internal variables such as lubricant film thickness, tooling roughness, and workpiece roughness. In the present research, the punch friction tests which use a tensile strip experiment to simulate the stretching of sheet over a punch corner radius in a typical draw die are used to measure the effects of internal variables on friction in various stretching conditions. The measured friction coefficients increase with lower stretching speed and decrease if lubricant is applied at the interface between workpiece and cylindrical pin. Theoretical friction modeling, which includes the different lubrication regimes range from thick film, thin film, mixed regime and boundary regime, are presented. Numerical methods have been used to solve the governing differential equations with the known initial boundary conditions obtained from the experiments. The theoretical prediction shows the same trend as the experimental measurements.

The influence of surface texturing on the transition of the lubrication regimes between a piston ring and a cylinder liner

2016 ◽  
Vol 18 (8) ◽  
pp. 785-796 ◽  
Author(s):  
Chunxing Gu ◽  
Xianghui Meng ◽  
Youbai Xie ◽  
Di Zhang
Keyword(s):  
Piston Ring ◽  
Surface Texturing ◽  
Cylinder Liner ◽  
Mixed Lubrication ◽  
Textured Surface ◽  
Asperity Contact ◽  
Lubrication Regimes ◽  
Lubrication Regime ◽  
Mixed Lubrication Regime ◽  
Stribeck Curves

This article employs a mixed lubrication model to investigate the performance of the textured surface. The Jakobsson–Floberg–Olsson model is used to obtain the hydrodynamic support of the textured conjunction, while the calculation of the asperity contact load is based on the load-sharing concept. Based on the simulated Stribeck curves of the smooth surface and the textured surface, comparisons are conducted to study the effect of texturing under different lubrication regimes. It appears that the transition of lubrication regimes is influenced by the texturing parameters and the convergence degrees of conjunction. The presence of textures delays the appearance of the mixed lubrication regime and the boundary lubrication regime.

Film Thickness and Friction Measurement of Piston Ring Cylinder Liner Contact With Corresponding Modeling Including Mixed Lubrication

2004 ◽  
Author(s):  
Nathan W. Bolander ◽  
Brian D. Steenwyk ◽  
Ashwin Kumar ◽  
Farshid Sadeghi
Keyword(s):  
Film Thickness ◽  
Analytical Model ◽  
Piston Ring ◽  
Cylinder Liner ◽  
Mixed Lubrication ◽  
Lubricant Film ◽  
Asperity Contact ◽  
Lubricant Film Thickness ◽  
Lubrication Regimes ◽  
Experimental Apparatus

An experimental apparatus and an analytical model have been developed to investigate and determine the lubrication condition and frictional losses at the interface between a piston ring and cylinder liner. The experimental apparatus features twin fiber optic displacement sensors to accurately measure the lubricant film thickness and a tri-axial piezoelectric force transducer to simultaneously measure frictional force. An analytical mixed lubrication model featuring Elrod cavitation and a stochastic/deterministic approach for asperity contact was used to investigate the effects of boundary and mixed lubrication conditions at the ends-of-stroke. A comparison between experimental and analytical results indicated that they are in good agreement. The results illustrate the transition through all of the different lubrication regimes (i.e. boundary, mixed and hydrodynamic lubrication) the piston ring and liner experience during a stroke. The twin displacement sensor arrangement is capable of producing accurate, repeatable measurements of lubricant film thickness that are in agreement with the analytical predictions. The analytical model developed for this study can capture the different lubrication regimes that the piston ring and liner experience.

scholarly journals Study on Friction in Automotive Shock Absorbers Part 1: Friction Simulation Using a Dynamic Friction Model in the Contact Zone of an FEM Model

Vehicles ◽  
2021 ◽  
Vol 3 (2) ◽  
pp. 212-232
Author(s):  
Ludwig Herzog ◽  
Klaus Augsburg
Keyword(s):  
Ride Comfort ◽  
Viscous Friction ◽  
Simulation Method ◽  
Friction Model ◽  
Model Parameters ◽  
Dynamic Friction ◽  
Friction Modeling ◽  
Shock Absorbers ◽  
Operation Conditions ◽  
Wide Range

The important change in the transition from partial to high automation is that a vehicle can drive autonomously, without active human involvement. This fact increases the current requirements regarding ride comfort and dictates new challenges for automotive shock absorbers. There exist two common types of automotive shock absorber with two friction types: The intended viscous friction dissipates the chassis vibrations, while the unwanted solid body friction is generated by the rubbing of the damper’s seals and guides during actuation. The latter so-called static friction impairs ride comfort and demands appropriate friction modeling for the control of adaptive or active suspension systems. In this article, a simulation approach is introduced to model damper friction based on the most friction-relevant parameters. Since damper friction is highly dependent on geometry, which can vary widely, three-dimensional (3D) structural FEM is used to determine the deformations of the damper parts resulting from mounting and varying operation conditions. In the respective contact zones, a dynamic friction model is applied and parameterized based on the single friction point measurements. Subsequent to the parameterization of the overall friction model with geometry data, operation conditions, material properties and friction model parameters, single friction point simulations are performed, analyzed and validated against single friction point measurements. It is shown that this simulation method allows for friction prediction with high accuracy. Consequently, its application enables a wide range of parameters relevant to damper friction to be investigated with significantly increased development efficiency.

scholarly journals Structural Damping with Friction Beams

2008 ◽  
Vol 15 (3-4) ◽  
pp. 291-298 ◽  
Author(s):  
L. Gaul ◽  
J. Roseira ◽  
J. Becker
Keyword(s):  
Linear Models ◽  
Natural Frequencies ◽  
Normal Force ◽  
Normal Pressure ◽  
Friction Model ◽  
Mode Shapes ◽  
Work Piece ◽  
Numerical Predictions ◽  
Double Beam ◽  
Excitation Force

In the last several years, there has been increasing interest in the use of friction joints for enhancing damping in structures. The joints themselves are responsible for the major part of the energy dissipation in assembled structures. The dissipated work in a joint depends on both the applied normal force and the excitation force. For the case of a constant amplitude excitation force, there is an optimal normal force which maximizes the damping. A ‘passive’ approach would be employed in this instance. In most cases however, the excitation force, as well as the interface parameters such as the friction coefficient, normal pressure distribution, etc., are not constant. In these cases, a ‘semi-active’ approach, which implements an active varying normal force, is necessary. For the ‘passive’ and ‘semi-active’ approaches, the normal force has to be measured. Interestingly, since the normal force in a friction joint influences the local stiffness, the natural frequencies of the assembled structure can be tuned by adjusting the normal force. Experiments and simulations are performed for a simple laboratory structure consisting of two superposed beams with friction in the interface. Numerical simulation of the friction interface requires non-linear models. The response of the double beam system is simulated using a numerical algorithm programmed inMATLABwhich models point-to-point friction with the Masing friction model. Numerical predictions and measurements of the double beam free vibration response are compared. A practical application is then described, in which a friction beam is used to damp the vibrations of the work piece table on a milling machine. The increased damping of the table reduces vibration amplitudes, which in turn results in enhanced surface quality of the machined parts, reduction in machine tool wear, and potentially higher feed rates. Optimal positioning of the friction beams is based on knowledge of the mode shapes, which are obtained from experimental modal analysis. The modal damping and the natural frequencies for the two dominant modes are measured for several combinations of excitation force and normal force.

Viscous Friction Effect During the Process of Tightening and Loosening of Bolted Joints

2021 ◽  
Author(s):  
Qingyuan Lin ◽  
Yong Zhao ◽  
Qingchao Sun ◽  
Kunyong Chen
Keyword(s):  
Friction Coefficient ◽  
Viscous Friction ◽  
Normal Pressure ◽  
Friction Model ◽  
Bolted Joints ◽  
Critical Parameters ◽  
Bolted Joint ◽  
Sliding Velocity ◽  
Friction Effect ◽  
Bearing Friction

Abstract Bolted connection is one of the most widely used mechanical connections because of its easiness of installation and disassembly. Research of bolted joints mainly focuses on two aspects: high precision tightening and improvement of anti-loosening performance. The under-head bearing friction coefficient and the thread friction coefficient are the two most important parameters that affect the tightening result of the bolted joint. They are also the most critical parameters that affect the anti-loosening performance of the bolted joint. Coulomb friction model is a commonly used model to describe under-head bearing friction and thread friction, which considers the friction coefficient as a constant independent of normal pressure and relative sliding velocity. In this paper, the viscous effect of the under-head bearing friction and thread friction is observed by measuring the friction coefficient of bolted joints. The value of the friction coefficient increases with the increase of the relative sliding velocity and the decrease of the normal pressure. It is found that the Coulomb viscous friction model can better describe the friction coefficient of bolted joints. Taking into account the dense friction effect, the loosening prediction model of bolted joints is modified. The experimental results show that the Coulomb viscous friction model can better describe the under-head bearing friction coefficient and thread friction coefficient. The model considering the dense effect can more accurately predict the loosening characteristics of bolted joints.

Numerical Investigation of Size Effect on Dry Friction Behavior in Micro Upsetting Process

2014 ◽  
Vol 997 ◽  
pp. 321-324
Author(s):  
Wei Zheng ◽  
Guang Chun Wang ◽  
Bing Tao Tang ◽  
Xiao Juan Lin ◽  
Yan Zhi Sun
Keyword(s):  
Friction Coefficient ◽  
Size Effect ◽  
Dry Friction ◽  
Normal Pressure ◽  
Friction Model ◽  
Strain Hardening Exponent ◽  
Forming Process ◽  
Friction Behavior ◽  
Initial Yield Stress ◽  
Coulomb’S Friction

After modifying the Wahime/Bay friction model, a new friction model suitable for micro-forming process without lubrication is established. In this model, it is shows that the friction coefficient is a function of strain hardening exponent, the normal pressure and the initial yield stress of material. Based on the experimental data, the micro-upsetting process is simulated using the proposed friction model. The simulation results are used to investigate the size effect on the dry friction behavior. It is found that the Coulomb’s friction coefficient is dropping with miniaturization of specimens when the amount of reduction is not too large.

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