Study on Surface Parameters of Asperity Flattening in Sliding Contact for Metallic Thin Film on Die Material during Metal Forming

This study applies the finite element method (FEM) in conjunction with an abductive network to predict the workpiece surface parameters, including contact area ratio, surface roughness, skewness and kurtosis, of asperity flattening in sliding contact for metallic thin film on die material during the metal forming process. Contact area ratio, surface roughness, skewness and kurtosis are investigated for different process and material parameters, such as sliding distance, elastic modulus of film, normal pressure and bulk strain rate by finite element analysis. The abductive network is then utilized to synthesize the data sets obtained from numerical simulations, and the prediction model is established for predicting surface parameters. The predicted results of the surface parameters from the prediction model are in good agreement with the results obtained from the FEM simulation of workpiece asperity flattening in sliding contact for metallic thin film on die material.