Lubricant Modeling and Its Effect on Simulation of Material Forming

1989 ◽  
Vol 111 (1) ◽  
pp. 74-80 ◽  
Author(s):  
J. E. Jackson ◽  
T. Gangjee ◽  
I. Haque
Keyword(s):  
Friction Factor ◽  
Analytical Models ◽  
Constant Shear ◽  
Shear Friction ◽  
Solid Film ◽  
Shear Friction Factor ◽  
Condition Modeling ◽  
Near Net Shape ◽  
Net Shape Forming ◽  
Material Forming

Solid cylinder upsetting is analyzed using three different approaches for frictional boundary condition modeling. These are (1) constant shear friction factor, (2) experimentally measured frictional stresses, and (3) analytical models accounting for lubricant entrapment and redistribution. All three approaches are implemented in the CFORM finite element code. The error between the three approaches and actual experimental measurements of the material deformation and interfacial pressures is investigated. It is shown that the constant shear friction factor is more accurate for solid film lubricants than for liquid lubricants. However, the calculations indicate that if accurate prediction of near net shape forming processes is to become a reality, improvements need to be made in the characterization of frictional boundary conditions. New theoretical developments applicable to arbitrary shapes and more accurate than the constant shear friction factor approach are needed.

Finite Element Simulation of Cutting Forces in Turning Ti6Al4V Using DEFORM 3D

2013 ◽  
Author(s):  
Kosaraju Satyanarayana ◽  
Anne Venu Gopal ◽  
Popuri Bangaru Babu
Keyword(s):  
Heat Transfer ◽  
Finite Element ◽  
Heat Transfer Coefficient ◽  
Transfer Coefficient ◽  
Friction Factor ◽  
Cutting Forces ◽  
Experimental Results ◽  
Shear Friction ◽  
Shear Friction Factor ◽  
Deform 3D

Titanium alloys are widely used in aerospace industry due to their excellent mechanical properties though they are classified as difficult to machine materials. As the experimental tests are costly and time demanding, metal cutting modeling provides an alternative way for better understanding of machining processes under different cutting conditions. In the present work, a finite element modeling software, DEFORM 3D has been used to simulate the machining of titanium alloy Ti6Al4V to predict the cutting forces. Experiments were conducted on a precision lathe machine using Ti6Al4V as workpiece material and TiAlN coated inserts as cutting tool. L9 orthogonal array based on design of experiments was used to evaluate the effect of process parameters such as cutting speed and feed with a constant depth of cut 0.25 mm and also the tool geometry such as rake angle on cutting force and temperature. These results were then used for estimation of heat transfer coefficient and shear friction factor constant, which are used as boundary conditions in the process of simulation. Upon simulations a relative error of maximum 9.07% was observed when compared with experimental results. A methodology was adopted to standardize these constants for a given process by taking average values of shear friction factor and heat transfer coefficient, which are used for further simulations within the range of parameters used during experimentation. A maximum error of 9.94% was observed when these simulation results are compared with that of experimental results.

Determination of a Dimensionless Equation for Shear Friction Factor in Cold Forging

2013 ◽  
Vol 135 (3) ◽  
Author(s):  
K. H. Jung ◽  
Y. T. Im
Keyword(s):  
Friction Factor ◽  
Friction Model ◽  
Cold Forging ◽  
Practical Applications ◽  
Dimensionless Equation ◽  
Bulk Forming ◽  
Highly Nonlinear ◽  
Shear Friction ◽  
Shear Friction Factor ◽  
Cold Bulk

In cold bulk forming processes, a constant shear friction model is widely used to apply friction. However, it is not easy to predict the shear friction factor since frictional behavior is highly nonlinear and is dependent upon a number of processing variables, such as the hardness of the material, lubricity, sliding velocity, surface contact conditions, and the environment, etc. This paper presents a dimensionless equation that predicts the shear friction factor at the counter punch interface mfd that was empirically determined by dimensional analysis, using the tip test results available in the literature as a function of selected process variables, such as the yield strength and initial specimen's radius of the deforming material, hardness, and surface roughness of the deforming material and the counter punch, viscosity of the lubricant, and deformation speed. To verify the determined equation, a new set of experiments were carried out for specimens made of AL7075-O. The prediction of the shear friction factor at the punch interface was also achieved by simply dividing the dimensionless equation by the x ratio defined by x = mfd/mfp, which is dependent on the hardening exponent of the deforming material based on previous studies. The predicted mfd and mfp were found to be reasonable owing to comparisons with the experimental data obtained for AL7075–O in this study. These results will be beneficial in scientifically assessing the effect of the processing parameters on the friction, individually and economically selecting the lubrication condition for cold bulk forming for practical applications.

Finite Element Investigation of Friction Condition in a Backward Extrusion of Aluminum Alloy

2003 ◽  
Vol 125 (2) ◽  
pp. 378-383 ◽  
Author(s):  
Yong-Taek Im ◽  
Seong-Hoon Kang ◽  
Jae-Seung Cheon
Keyword(s):  
Finite Element ◽  
Linear Relationship ◽  
Friction Factor ◽  
Friction Condition ◽  
Global Average ◽  
Backward Extrusion ◽  
Shear Friction ◽  
Shear Friction Factor ◽  
Tip Test ◽  
The One

Finite element simulations are being widely used to increase the efficiency and effectiveness of design of bulk metal forming processes. In such simulations, proper consideration of friction condition is important in obtaining reliable results. For this purpose, the shear friction factor is widely used for bulk deformation analyses. In the earlier work, it was found that a radial tip was formed on the extruded end of the workpiece and that the radial tip distance had a linear relationship with the forming load in the tip test. In order to characterize the global average shear friction factor, a linear relationship between the nondimensionalized radial tip distance and shear friction factor was numerically determined in this study for AL6061-O for various lubrication conditions. The global average friction condition at the bottom die interface was determined to be about 60 percent of the one at the punch in the backward extrusion under the present conditions.

Mechanical Design for Accuracy of Linkage Servo Press for Near-Net Shape Forming

2018 ◽  
Author(s):  
Jing Tao ◽  
Huanan Qian ◽  
Suiran Yu
Keyword(s):  
Mechanical Design ◽  
Structure Design ◽  
Tolerance Allocation ◽  
Component Level ◽  
Eccentric Load ◽  
Servo Press ◽  
Near Net Shape ◽  
Net Shape Forming ◽  
Heavy Loads

The accuracy of machine is important to achieving highly accurate shapes. This paper is focused on mechanical design of highly accurate mechanical linkage servo press applicable to (near-)net shape forming. The effects of geometric errors, deformations under heavy loads and ram tilting are analyzed. A top-down design for accuracy approach is proposed: First, accuracy model for identification of inaccuracy-causing factors and their interlinking relations is developed. Then, based on this model, top accuracy index are decomposed and translated into structure design specifications at component level. Both analytic and simulation methods are employed for design for accuracy in aspects of dimensional and geometric tolerance allocation, stiffness synthesis and anti-eccentric load capability. A case study of mechanical design for accuracy of a six-linkage mechanical servo press is also presented to demonstrate and test the proposed design approaches.

Analysis of a Thixo-Lateral Forged Spindle from LTT C45, LTT C38 and LTT 100Cr6 Steel Grades

2014 ◽  
Vol 217-218 ◽  
pp. 347-354 ◽  
Author(s):  
Jokin Lozares ◽  
Zigor Azpilgain ◽  
Iñaki Hurtado ◽  
Iñigo Loizaga
Keyword(s):  
Mechanical Properties ◽  
Current Trend ◽  
Research Work ◽  
Raw Material ◽  
Key Factor ◽  
Steel Grades ◽  
Near Net Shape ◽  
Net Shape Forming ◽  
Near Net Shaping ◽  
Net Shaping

Due to the current trend in prices of raw material and their sources, near net shaping of mechanical components will become a key factor for the companies to get the desired competitiveness. Semisolid metal (SSM) forming is one of those near net shape forming techniques revealing a high potential to reduce material as well as energy consumption compared to conventional process technologies. Thus, the aim of this research work is to demonstrate the above by manufacturing a steel commercial automotive spindle by thixo-lateral forming from three different steel grades. The starting material, the microstructure and mechanical properties are analysed along the article. Material savings of 20% have been reported together with a substantial decrease of the forming forces. In addition, great mechanical properties have been achieved which brings the process closer to the desired final industrial application.

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