Friction analysis in bulk metal forming

Abstract

A methodology to characterize friction according to the severe conditions of contact encountered in metal forming is presented. The main peculiarity of the proposed method is to use specimens and contactor made of industrial tool and workpiece surface in laboratory bench tests in order to ensure their representativeness regarding to the real process. Four steps are then required to identify friction: measurement/computation of mechanical loading on the process to be simulated in the lab (sliding velocities, contact pressures, plastic strains), machining of specimens and contactors, adjustment of the friction test to simulate the target loading, analyzes of the results in terms of friction and lubricant efficiency. Examples are presented to exhibit the reliability and flexibility of the methodology.