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 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.

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 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.

scholarly journals Assessment of Linearization Approaches for Multibody Dynamics Formulations

2017 ◽  
Vol 12 (4) ◽  
Author(s):  
Francisco González ◽  
Pierangelo Masarati ◽  
Javier Cuadrado ◽  
Miguel A. Naya
Keyword(s):  
Mechanical System ◽  
Multibody Dynamics ◽  
Equations Of Motion ◽  
Differential Algebraic Equations ◽  
Algebraic Equations ◽  
Practical Applications ◽  
Linearization Methods ◽  
Highly Nonlinear ◽  
Wide Range ◽  
The Way

Formulating the dynamics equations of a mechanical system following a multibody dynamics approach often leads to a set of highly nonlinear differential-algebraic equations (DAEs). While this form of the equations of motion is suitable for a wide range of practical applications, in some cases it is necessary to have access to the linearized system dynamics. This is the case when stability and modal analyses are to be carried out; the definition of plant and system models for certain control algorithms and state estimators also requires a linear expression of the dynamics. A number of methods for the linearization of multibody dynamics can be found in the literature. They differ in both the approach that they follow to handle the equations of motion and the way in which they deliver their results, which in turn are determined by the selection of the generalized coordinates used to describe the mechanical system. This selection is closely related to the way in which the kinematic constraints of the system are treated. Three major approaches can be distinguished and used to categorize most of the linearization methods published so far. In this work, we demonstrate the properties of each approach in the linearization of systems in static equilibrium, illustrating them with the study of two representative examples.

Stick-Slip Compensation of Micro-Positioning Using Elastic-Plastic Static Friction Model

2008 ◽  
Vol 47-50 ◽  
pp. 246-249
Author(s):  
Min Gyu Jang ◽  
Chul Hee Lee ◽  
Seung Bok Choi
Keyword(s):  
Static Friction ◽  
Friction Model ◽  
Smart Structure ◽  
Asperity Contact ◽  
Stick Slip ◽  
Elastic Plastic ◽  
Highly Nonlinear ◽  
Bridge Type ◽  
Structural Parts ◽  
Rough Surface Contact

In this paper, a stick-slip compensation for the micro-positioning is presented using the statistical rough surface contact model. As for the micro-positioning structure, PZT (lead(Pb) zirconia(Zr) Titanate(Ti)) actuator is used to drive the load for precise positioning with its high resolution incorporating with the PID (Proportional Integral Derivative) control algorithm. Since the stick-slip characteristics for the micro structures are highly nonlinear and complicated, it is necessary to incorporate more detailed stick-slip model for the applications involving the high precision motion control. Thus, the elastic-plastic static friction model is used for the stick-slip compensation considering the elastic-plastic asperity contact in the rough surfaces statistically. Mathematical model of the system for the positioning apparatus was derived from the dynamic behaviors of structural parts. Since the conventional piezoelectric actuator generates the short stroke, a bridge-type flexural hinge mechanism is introduced to amplify the linear motion range. Using the proposed smart structure, simulations under the representative positioning motion were conducted to demonstrate the micro-positioning under the stick-slip friction.

Adhesive and normal stress-dependent dynamic friction of a gelatin hydrogel

2021 ◽  
pp. 135065012110446
Author(s):  
Nitish Sinha ◽  
Arun Kumar Singh ◽  
Vinit Gupta ◽  
Jitendra Kumar Katiyar
Keyword(s):  
Experimental Data ◽  
Normal Stress ◽  
Scaling Law ◽  
Shear Velocity ◽  
Friction Model ◽  
Dynamic Friction ◽  
Practical Applications ◽  
Soft Solids ◽  
Gelatin Hydrogel ◽  
Stress Dependent

Adhesion and friction of soft solids on hard surfaces are the important properties for a variety of practical applications. In the present study, Coulomb's law of friction is used for characterizing adhesive friction as well as normal stress-dependent dynamic friction of a gelatin hydrogel on a fixed glass surface. The experimental data, concerning normal stress-dependent dynamic friction of different shear velocity, are obtained from literature. It is observed that both components of friction increase with shear velocity. More importantly, the scaling law shows that adhesive stress varies almost linearly with corresponding coefficient of friction of the hydrogel. A dynamic friction model is also used to analyze the same experimental data to predict a negative normal stress at which dynamic friction reduces to zero, and this result matches closely with the experimental value.

scholarly journals Numerical Investigation of Aligned Magnetic Flow Comprising Nanoliquid over a Radial Stretchable Surface with Cattaneo–Christov Heat Flux with Entropy Generation

Symmetry ◽  
2019 ◽  
Vol 11 (12) ◽  
pp. 1520 ◽  
Author(s):  
A. Zaib ◽  
Umair Khan ◽  
Ilyas Khan ◽  
Asiful H. Seikh ◽  
El-Sayed M. Sherif
Keyword(s):  
Heat Flux ◽  
Friction Factor ◽  
Entropy Generation ◽  
Liquid Velocity ◽  
Thermal Relaxation ◽  
Magnetic Flow ◽  
Magnetic Parameters ◽  
Highly Nonlinear ◽  
Nanoparticles Concentration ◽  
Mass And Heat Transfer

The influence of entropy generation on aligned magnetic flow-including nanoparticles through a convectively heated radial stretched surface in the existence of Cattaneo–Christov heat flux is inspected. The highly nonlinear leading PDE’s via the similar scaling transformation are developed. The resulting system via the bvp4c technique from Matlab is computed. The impacts of rising constraints on the liquid velocity, nanoparticles concentration and temperature profile are argued and showed via portraits and table. In addition, the performance of liquid flow is inspected through the friction factor, the mass and heat transfer rate. With the rise in the thermal relaxation constraint, the thermal boundary layer is appreciably altered. Due to an aligned angle, the velocity of nanoliquid declines, while the concentration and temperature of nanofluid augment. It is also observed that the values of friction factor increase, whereas the values of heat and mass transfer decline due to an aligned angle. Entropy generation profiles developed due to magnetic parameters and the aligned angle. Lastly, a comparative scrutiny is composed via the previous studies which lead to support for our presently developed model.

Studies Concerning Numerical Prediction of Metal Fibering Obtained by Cold Bulk Forming Using Sensitivity Analysis of Tribological and Rheological Properties on a Cylindrical Crushing Process

2016 ◽  
Vol 841 ◽  
pp. 29-38
Author(s):  
Adinel Gavrus ◽  
Daniela Pintilie ◽  
Roxana Nedelcu
Keyword(s):  
Sensitivity Analysis ◽  
Constitutive Behavior ◽  
Rheological Equation ◽  
Metallic Material ◽  
High Importance ◽  
Friction Law ◽  
Bulk Forming ◽  
Cold Bulk ◽  
Abaqus Software ◽  
Softening Term

The present research paper concerns a numerical and experimental analysis of the tribologic and rheological constitutive behavior influence on prediction of metallic material forging fibering. Numerical analysis using finite element Forge® code and Abaqus software show the high importance of the friction law formulation and of the material rheological softening on the fibers morphology and on their position coordinates. Calibration and sensitivity of friction law together with the numerical sensitivity of the softening term corresponding to a Hansel-Spittel rheological equation have been studied for a cylindrical crushing test of a 16MnCr5 steel.

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