Tribology International
journal homepage: www.elsevier.com/locate/triboint
a r t i c l e in fo abstract
Article history: In this paper, the Coulomb friction law and the constant shear friction law were compared and
Received 20 August 2007 investigated in detail using a rigid-plastic finite element method with emphasis on their application in
Received in revised form bulk metal forming. The ring compression test for two different materials was used to evaluate the two
19 June 2008
friction laws, and then their effects on metal flow lines and forming loads for various friction-sensitive
Accepted 24 June 2008
Available online 26 July 2008
metal forming processes including strip rolling, ring gear forging, multistep extrusion, and pipe
shrinkage and expansion were investigated. It was shown that considerable differences exist between
Keywords: the two friction laws, especially in friction-sensitive metal forming processes.
Bulk metal forming & 2008 Elsevier Ltd. All rights reserved.
Friction law
Friction-sensitive metal forming process
Coulomb friction law
Constant shear friction law
0301-679X/$ - see front matter & 2008 Elsevier Ltd. All rights reserved.
doi:10.1016/j.triboint.2008.06.012
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m = 0.40
2. Rigid-plastic finite element formulation with emphasis on 40 µ = 0.16
friction laws
X 100%
30 m = 0.30
d0-d
problem. The material is denoted as the domain V with boundary
d0
10 m = 0.20
S. The boundary S can be divided into the velocity-prescribed µ = 0.08
boundary Svi , where the velocity is given as vi ¼ v̄i ; the traction- 0
n
prescribed boundary Sti , where the stress vector is given as t ni ¼ t̄ i ;
and the die–workpiece interface Sc, where the no-penetration -10
m = 0.10
condition, vn ¼ v̄n , is maintained when the interface is in
compression. It is assumed that the material is incompressible, -20
µ = 0.04
i.e., ni,i ¼ 0, isotropic, and rigid-viscoplastic. It is further assumed
-30
that the material obeys the Huber–von Mises yield criterion and 0 10 20 30 40 50 60
its associated flow rule, which is
h0-h
2s̄ Reduction in height, X 100%
s0ij ¼ _ _ ij (1) h0
3¯
where s0ij and _ ij are the deviatoric stress tensor and strain-rate Fig. 2. Friction evaluation curves for a material at the elevated temperature,
tensor, respectively. The flow stress s̄ in Eq. (1) is assumed to be a obtained by ring compression simulation.
C
L
h0
d0/2 dmin/2
h
70
µ = 0.24
Reduction in minimum in ternal diameter,
m = 0.30
µ = 0.12
20
d0-d
d0
10 m = 0.20
µ = 0.08
0
-10
m = 0.10
-20 µ = 0.04
-30
0 10 20 3040 50 60
h0-h
Reduction in height, X 100%
h0
Fig. 1. Friction evaluation curves for a material at the room temperature, obtained by ring compression simulation: (a) ring compression and (b) calibration curves.
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Fig. 3. Comparison of metal flow lines formed from compression of the ring with
small aspect ratio and small ratio of contact region: (a) Coulomb friction law and
(b) constant shear frictional law.
140
100
Load (kN)
80
60
Fig. 5. Comparison of metal flow lines formed from compression of the ring with
40 large aspect ratio and large ratio of contact region: (a) Coulomb friction law and (b)
constant shear friction law.
20
function of the effective strain ¯ and the effective strain rate _¯ , i.e.,
s̄ ¼ s̄ð¯; _¯ Þ. It is also assumed that the effect of acceleration
0
0 10 20 30 40 50 60 70 and gravity on force equilibrium is negligible, and that the
process is isothermal. Thus, the equation of equilibrium can be
Stroke (mm)
written as
Fig. 4. Stroke-forming load curves of the ring compression with small aspect ratio
and small ratio of contact region. sij;j þ f i ¼ 0 (2)
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750 40
µ = 0.1
µ = 0.2
Coulomb friction µ = 0.3
30 max
Constant shear friction µ = 0.4
600 Roll
µ = 0.5
µ = 0.6
µ = 0.7 Strip
20 m = 1.0
x 100
450
Load (kN)
10
vt
|vt|
vt
300
0
150 -10
-20
0 0 0.2 0.4 0.6 0.8 1
0 5 10 15 20 25
Normalized angle of contact (/max)
Stroke (mm)
Fig. 7. Variation of sticking region with frictional conditions.
Fig. 6. Stroke-forming load curves of the ring compression with large aspect ratio
and large ratio of contact region.
Using the penalty method for the incompressibility condition, the 16c
weak form of the above boundary value problem can be written as µ = 0.1
Z Z Z µ = 0.2
XZ 14c µ = 0.3
s0ij o0ij dV þ K ii ojj dV f i oi dV t̄ i oi dS µ = 0.4
V V V Sti µ= 0.5
Z
12c µ = 0.6
st ot dS ¼ 0 (3) µ = 0.7
Sc m = 1.0
10c sticking
Roll pressure
Fig. 9. Variation of metal flow lines with the two frictional laws: (a) Coulomb friction law and (b) constant shear friction law.
12000
Coulomb friction
10000
Constant shear friction
8000
Load (kN)
6000
4000
2000
0 10 20 30 40 50
Stroke (mm)
Fig. 10. Detailed comparison of metal flow lines: (a) Coulomb friction law and (b)
constant shear friction law. Fig. 11. Comparison of forming loads in the ring gear forging, predicted by the two
different frictional laws.
conditions [10,30–34]. Specifically, the inner and outer radii of the finite element analysis, one can construct the friction evaluation
deformed ring vary with respect to its height, and the deformation curves by plotting the minimum ring radius versus height. For
pattern is highly dependent on the friction conditions. Through example, Fig. 1 shows the friction evaluation curves for a material
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1.0 1.0
4. Effects of friction laws and conditions Die
The aspect ratio of the process is defined as the width of the Fig. 12. Variation of plastic region and effective strain with the Coulomb friction
material divided by its height. The ratio of the contact region is coefficients: (a) variant Coulomb friction coefficient and (b) constant Coulomb
friction coefficient.
the area of the die–material interface divided by the entire surface
area of the material.
Hot strip rolling is a representative example of a process with a Fig. 13. A long-pipe simultaneously shrinking and expanding process: (a) initial
large aspect ratio and a large contact ratio. Thus, it is the extreme and (b) final.
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= 0.75 m = 0.153
Fig. 14. Simulation results: (a) simulation results for m (m) ¼ 0.025(0.043), (b) simulation results for m (m) ¼ 0.050(0.096), and (c) simulation results for m
(m) ¼ 0.075(0.153).
case in studying the two friction laws. The parameters we used for m ¼ 0.2. This can be seen again in Fig. 8, which shows the roll
the hot strip rolling process were roll diameter, 400 mm; initial pressure distribution or the friction hill. The predicted results
strip thickness, 2 mm; reduction ratio, 40%; strain-rate hardening demonstrate that the sticking region increases as the Coulomb
0:196
exponent, 0.195 (flow stress: s̄ ¼ c_¯ where c is a material friction coefficient increases but that the constant shear friction
constant); and roll speed, v̄t ¼ 1256:64 mm=s. This example was law cannot predict the distinct sticking phenomena even with the
solved using the penalty rigid-viscoplastic finite element method maximum value of m ¼ 1.0. Fig. 8 shows that the constant shear
[27] for calculating the normal stress accurately without any friction law imposes excessive friction around the exit and entry
iteration. but that it reduces the friction in the middle region near the
Fig. 7 shows the relative velocity of the material with respect to neutral point.
the roll along the roll–material interface. From the figure, we can We therefore concluded that the friction evaluation curves are
see that the results obtained for m ¼ 1.0 are nearly the same as for irrelevant to hot strip rolling.
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