Journal Home > Volume 12 , Issue 3
Friction 2024, 12(3): 396-427 https://doi.org/10.1007/s40544-023-0761-7
Review Article | Open Access | Issue | Published: 04 July 2023

Advances in friction of aluminium alloy deep drawing

Show Author's Information Yiren GAO,  Hongxia LI( ),  Danyang ZHAO,  Minjie WANG,  Xiaobo FAN
School of Mechanical Engineering, Dalian University of Technology, Dalian 116023, China
Keywords:
friction model, influencing factors, friction control, aluminium alloy deep drawing (AADD), friction measurement
Cite this article:
GAO Y, LI H, ZHAO D, et al. Advances in friction of aluminium alloy deep drawing. Friction, 2024, 12(3): 396-427. https://doi.org/10.1007/s40544-023-0761-7
Download citation
EndNote(RIS)
BibTeX

257

Views

71

Downloads

Citations

2

Crossref

3

WoS

3

Scopus

0

CSCD

Abstract Full text About this article

Broad use of lightweight aluminium alloy parts in automobile manufacturing, aerospace, electronic communication, and rail transit is mainly formed through deep drawing process. Deep drawing friction is a key boundary condition for controlling the forming quality of aluminium alloy parts. However, due to the oxidation and adhesion tendency of aluminium alloys, the tribological situations of aluminium alloy deep drawing (AADD) system is more complicated than those of traditional deep drawing of steel sheets. Therefore, the study of AADD friction is essential for manufacturing high-performance aluminium alloy parts. Herein, aiming to provide a valuable reference for researchers in related fields, a comprehensive review of AADD friction is provided, including friction mechanism, influencing factors, friction measurement, friction model, friction simulation, and lubrication-free friction control. Finally, a brief conclusion and several current challenges were discussed.


menu
Abstract
Full text
Outline
About this article

Advances in friction of aluminium alloy deep drawing

Show Author's information Yiren GAO, Hongxia LI( ), Danyang ZHAO, Minjie WANG, Xiaobo FAN
School of Mechanical Engineering, Dalian University of Technology, Dalian 116023, China

Abstract

Broad use of lightweight aluminium alloy parts in automobile manufacturing, aerospace, electronic communication, and rail transit is mainly formed through deep drawing process. Deep drawing friction is a key boundary condition for controlling the forming quality of aluminium alloy parts. However, due to the oxidation and adhesion tendency of aluminium alloys, the tribological situations of aluminium alloy deep drawing (AADD) system is more complicated than those of traditional deep drawing of steel sheets. Therefore, the study of AADD friction is essential for manufacturing high-performance aluminium alloy parts. Herein, aiming to provide a valuable reference for researchers in related fields, a comprehensive review of AADD friction is provided, including friction mechanism, influencing factors, friction measurement, friction model, friction simulation, and lubrication-free friction control. Finally, a brief conclusion and several current challenges were discussed.

Keywords: friction model, influencing factors, friction control, aluminium alloy deep drawing (AADD), friction measurement

References(164)

[1]
Schneider R, Grant R J, Schlosser J M, Rimkus W, Radlmayr K, Grabner F, Maier C. An investigation of the deep drawing behavior of automotive aluminium alloys at very low temperatures. Metall Mater Trans A 51(3): 1123–1133 (2020)
DOI Google Scholar
[2]
Tatipala S, Wall J, Johansson C M, Sigvant M. Data-driven modelling in the era of Industry 4.0: A case study of friction modelling in sheet metal forming simulations. J Phys Conf Ser 1063: 012135 (2018)
DOI Google Scholar
[3]
Tatipala S, Pilthammar J, Sigvant M, Wall J, Johansson C M. Introductory study of sheet metal forming simulations to evaluate process robustness. IOP Conf Ser Mater Sci Eng 418: 012111 (2018)
DOI Google Scholar
[4]
Veldhuis M, Heingärtner J, Krairi A, Waanders D, Hazrati J. An industrial-scale cold forming process highly sensitive to temperature induced frictional start-up effects to validate a physical based friction model. Procedia Manuf 47: 578–585 (2020)
DOI Google Scholar
[5]
Krairi A, Marmi J, Gastebois S, Veldhuis M, Kott M. A speed-up method for numerical simulations of multi-strokes cold metallic sheet forming processes. Procedia Manuf 47: 570–577 (2020)
DOI Google Scholar
[6]
Kalpakjian S. Recent progress in metal forming tribology. J Appl Metalworking 4(3): 270–280 (1986)
DOI Google Scholar
[7]
Kawai N, Dohda K. Development of tribology in metal forming. JSME Int J 30(265): 1018–1025 (1987)
DOI Google Scholar
[8]
Guo L, Li G Y, Zhong Z H, Chen F Z. Advances in friction models of computer simulation of stamping of sheet metal. China Mechanical Engineering 14(21): 1879–1882 (2003) (in Chinese)
Google Scholar
[9]
Meng L F, Hu C L, Zhao Z. Research progress of friction model in metal plastic forming. Die & Mould Industry 40(4): 1–7 (2014) (in Chinese)
Google Scholar
[10]
Seshacharyulu K, Bandhavi C, Naik B B, Rao S S, Singh S K. Understanding friction in sheet metal forming—A review. Mater Today 5(9): 18238–18244 (2018)
DOI Google Scholar
[11]
Xu N, Wang P, Xia J S, Zhang Z Y. Research progress of friction characteristics in plastic forming. Hot Work Technol 47(23): 5–11 (2018) (in Chinese)
Google Scholar
[12]
Nielsen C V, Bay N. Review of friction modeling in metal forming processes. J Mater Process Tech 255: 234–241 (2018)
DOI Google Scholar
[13]
Bowden F P, Tabor D. Mechanism of metallic friction. Nature 150(3798): 197–199 (1942)
DOI Google Scholar
[14]
Li G, Long X Y, Yang P, Liang Z K. Advance on friction of stamping forming. Int J Adv Manuf Tech 96(1–4): 21–38 (2018)
DOI Google Scholar
[15]
Trzepiecinski T, Lemu H G. Recent developments and trends in the friction testing for conventional sheet metal forming and incremental sheet forming. Metals 10(1): 47 (2020)
DOI Google Scholar
[16]
Groche P, Callies T. Tribology in sheet metal forming with regard to challenges in lightweight construction. Adv Mater Res 6–8: 93–100 (2005)
DOI Google Scholar
[17]
Westlund V, Heinrichs J, Jacobson S. On the role of material transfer in friction between metals: Initial phenomena and effects of roughness and boundary lubrication in sliding between aluminium and tool steels. Tribol Lett 66(3): 97 (2018)
DOI Google Scholar
[18]
Bouchaâla K, Ghanameh M F, Faqir M, Mada M, Essadiqi E. Evaluation of the effect of contact and friction on deep drawing formability analysis for lightweight aluminium lithium alloy using cylindrical cup. Procedia Manuf 46: 623–629 (2020)
DOI Google Scholar
[19]
Reddy G C M, Reddy P V R R, Reddy T A J. Finite element analysis of the effect of coefficient of friction on the drawability. Tribol Int 43(5–6): 1132–1137 (2010)
DOI Google Scholar
[20]
Folle L F, Schaeffer L. Effect of surface roughness and lubrication on the friction coefficient in deep drawing processes of aluminium alloy AA1100 with FEM analysis. Matéria (Rio de Janeiro) 24(1): e-12298 (2019)
DOI Google Scholar
[21]
Bellini C, Giuliano G, Sorrentino L. Friction influence on the AA6060 aluminium alloy formability. Fracture and Structural Integrity 13(49): 791–799 (2019)
DOI Google Scholar
[22]
Ma W Y, Wang B Y, Fu L, Zhou J, Huang M D. Effect of friction coefficient in deep drawing of AA6111 sheet at elevated temperatures. T Nonferr Metal Soc 25(7): 2342–2351 (2015)
DOI Google Scholar
[23]
Mohamed M, Farouk M, Elsayed A, Shazly M, Hegazy A A. An investigation of friction effect on formability of AA 6061-T4 sheet during cold forming condition. AIP Conf Proc 1896(1): 080025 (2017)
DOI Google Scholar
[24]
Lu J, Song Y L, Hua L, Zhou P, Xie G J. Effect of temperature on friction and galling behavior of 7075 aluminium alloy sheet based on ball-on-plate sliding test. Tribol Int 140: 105872 (2019)
DOI Google Scholar
[25]
Lu J, Song Y L, Zhou P, Lin J G, Dean T A, Liu P. Process parameters effect on high-temperature friction and galling characteristics of AA7075 sheets. Mater Manuf Process 36(8): 967–978 (2021)
DOI Google Scholar
[26]
Hanna M D. Tribological evaluation of aluminium and magnesium sheet forming at high temperatures. Wear 267(5–8): 1046–1050 (2009)
DOI Google Scholar
[27]
Gali O A, Riahi A R, Alpas A T. The tribological behaviour of AA5083 alloy plastically deformed at warm forming temperatures. Wear 302(1–2): 1257–1267 (2013)
DOI Google Scholar
[28]
Liu Y, Zhu Z J, Wang Z J, Zhu B, Wang Y L, Zhang Y S. Flow and friction behaviors of 6061 aluminium alloy at elevated temperatures and hot stamping of a B-pillar. Int J Adv Manuf Tech 96(9): 4063–4083 (2018)
DOI Google Scholar
[29]
Dou S S, Wang X P, Xia J, Wilson L. Analysis of sheet metal forming (warm stamping process): A study of the variable friction coefficient on 6111 aluminium alloy. Metals 10(9): 1189 (2020)
DOI Google Scholar
[30]
Grabner F, Gruber B, Schlögl C, Chimani C. Cryogenic sheet metal forming—An overview. Mater Sci Forum 941: 1397–1403 (2018)
DOI Google Scholar
[31]
Sotirov N, Falkinger G, Grabner F, Schmid G, Schneider R, Grant R J, Kelsch R, Radlmayr K, Scheerer M, Reichl C, et al. Improved formability of AA5182 aluminium alloy sheet at cryogenic temperatures. Mater Today 2: S113–S118 (2015)
DOI Google Scholar
[32]
Kumar M, Sotirov N, Grabner F, Schneider R, Mozdzen G. Cryogenic forming behaviour of AW-6016-T4 sheet. T Nonferr Metal Soc 27(6): 1257–1263 (2017)
DOI Google Scholar
[33]
Reichl C, Schneider R, Hohenauer W, Grabner F, Grant R J. A numerical simulation of thermodynamic processes for cryogenic metal forming of aluminium sheets and comparison with experimental results. Appl Therm Eng 113: 1228–1241 (2017)
DOI Google Scholar
[34]
Wang C G, Yi Y P, Huang S Q, Dong F, He H L, Huang K, Jia Y Z. Experimental and theoretical investigation on the forming limit of 2024-O aluminium alloy sheet at cryogenic temperatures. Met Mater Int 27(12): 5199–5211 (2021)
DOI Google Scholar
[35]
Padmini B V, Sampathkumaran P, Seetharamu S, Naveen G J, Niranjan H B. Investigation on the wear behaviour of aluminium alloys at cryogenic temperature and subjected to cryo-treatment. IOP Conf Ser Mater Sci Eng 502: 012191 (2019)
DOI Google Scholar
[36]
Lin J F, Wang L Y, Huang T K. Friction in deep drawing of aluminium sheet. Wear 156(1): 189–199 (1992)
DOI Google Scholar
[37]
Ooki K, Takahashi S. Investigation of high speed friction test for aluminium alloys. J Phys Conf Ser 734: 032040 (2016)
DOI Google Scholar
[38]
Hwang Y M, Chen C C. Investigation of effects of strip metals and relative sliding speeds on friction coefficients by reversible strip friction tests. Metals 10(10): 1369 (2020)
DOI Google Scholar
[39]
Sabet A S, Domitner J, Öksüz K I, Hodžić E, Torres H, Ripoll M R, Sommitsch C. Tribological investigations on aluminium alloys at different contact conditions for simulation of deep drawing processes. J Manuf Process 68: 546–557 (2021)
DOI Google Scholar
[40]
Steiner J, Merklein M. Investigation of influencing parameters for tribological conditions in dry forming processes. Acta Metall Sin-Engl 28(12): 1435–1441 (2015)
DOI Google Scholar
[41]
Gil I, Mendiguren J, Galdos L, Mugarra E, de Argandoña E S. Influence of the pressure dependent coefficient of friction on deep drawing springback predictions. Tribol Int 103: 266–273 (2016)
DOI Google Scholar
[42]
De Argandoña E S, Mendiguren J, Otero I, Mugarra E, Otegi N, Galdos L. Improving the prediction of the final part geometry in high strength steels U drawing by means of advanced material and friction models. AIP Conf Proc 1960(1): 170014 (2018)
DOI Google Scholar
[43]
Domitner J, Silvayeh Z, Sabet A S, Öksüz K I, Pelcastre L, Hardell J. Characterization of wear and friction between tool steel and aluminium alloys in sheet forming at room temperature. J Manuf Process 64: 774–784 (2021)
DOI Google Scholar
[44]
Yang X, Liu X C, Liu H L, Politis D J, Leyvraz D, Wang L L. Experimental and modelling study of friction evolution and lubricant breakdown behaviour under varying contact conditions in warm aluminium forming processes. Tribol Int 158: 106934 (2021)
DOI Google Scholar
[45]
Shi Z, Wang L, Mohamed M, Balint D S, Lin J, Stanton M, Watson D, Dean T A. A new design of friction test rig and determination of friction coefficient when warm forming an aluminium alloy. Procedia Eng 207: 2274–2279 (2017)
DOI Google Scholar
[46]
Hartfield-Wunsch S E, Cohen D, Sanchez L R, Brattstrom L E. The effect of surface finish on aluminium sheet friction behavior. SAE Int J Mater Manuf 4(1): 818–825 (2011)
DOI Google Scholar
[47]
Zhou R, Cao J, Wang Q J, Meng F M, Zimowski K, Xia Z C. Effect of EDT surface texturing on tribological behavior of aluminium sheet. J Mater Process Tech 211(10): 1643–1649 (2011)
DOI Google Scholar
[48]
Keum Y T, Wagoner R H, Lee J K. Friction model for FEM simulation of sheet metal forming operations. AIP Conf Proc 712: 989–994 (2004)
DOI Google Scholar
[49]
Lemu H G, Trzepieciński T. Numerical and experimental study of frictional behavior in bending under tension test. Stroj Vestn-J Mech E 59(1): 41–49 (2013)
DOI Google Scholar
[50]
Horiuchi T, Yoshihara S, Iriyama Y. Dry deep drawability of A5052 aluminium alloy sheet with DLC-coating. Wear 286–287: 79–83 (2012)
DOI Google Scholar
[51]
Abraham T, Bräuer G, Kretz F, Groche P. Observation of the a-C:H run-in behaviour for dry forming applications of aluminium. MATEC Web Conf 190: 14001 (2018)
DOI Google Scholar
[52]
Tenner J, Andreas K, Radius A, Merklein M. Numerical and experimental investigation of dry deep drawing of aluminium alloys with conventional and coated tool surfaces. Procedia Eng 207: 2245–2250 (2017)
DOI Google Scholar
[53]
Steiner J, Andreas K, Merklein M. Investigation of surface finishing of carbon based coated tools for dry deep drawing of aluminium alloys. IOP Conf Ser Mater Sci Eng 159: 012022 (2016)
DOI Google Scholar
[54]
Aktürk D A, Liu P Z, Cao J, Wang Q J, Xia Z C, Talwar R, Grzina D, Merklein M. Friction anisotropy of aluminium 6111-T4 sheet with flat and laser-textured D2 tooling. Tribol Int 81: 333–340 (2015)
DOI Google Scholar
[55]
Liu X J, Liewald M, Becker D. Effects of rolling direction and lubricant on friction in sheet metal forming. J Tribol 131(4): 042101 (2009)
DOI Google Scholar
[56]
Saha P K, Wilson W R D, Timsit R S. Influence of surface topography on the frictional characteristics of 3104 aluminium alloy sheet. Wear 197(1–2): 123–129 (1996)
DOI Google Scholar
[57]
Menezes P L, Kishore, Kailas S V. Studies on friction and transfer layer: Role of surface texture. Tribol Lett 24(3): 265–273 (2006)
DOI Google Scholar
[58]
Menezes P L, Kishore, Kailas S V. Influence of surface texture and roughness parameters on friction and transfer layer formation during sliding of aluminium pin on steel plate. Wear 267(9–10): 1534–1549 (2009)
DOI Google Scholar
[59]
Zabala A, Galdos L, Childs C, Llavori I, Aginagalde A, Mendiguren J, de Argandoña E S. The interaction between the sheet/tool surface texture and the friction/galling behaviour on aluminium deep drawing operations. Metals 11(6): 979 (2021)
DOI Google Scholar
[60]
Hu Y, Zheng Y, Politis D J, Masen M A, Cui J, Wang L. Development of an interactive friction model to predict aluminium transfer in a pin-on-disc sliding system. Tribol Int 130: 216–228 (2019)
DOI Google Scholar
[61]
Wilson W R D, Sheu S. Real area of contact and boundary friction in metal forming. Int J Mech Sci 30(7): 475–489 (1988)
DOI Google Scholar
[62]
Zhao R, Steiner J, Andreas K, Merklein M, Tremmel S. Investigation of tribological behaviour of a-C:H coatings for dry deep drawing of aluminium alloys. Tribol Int 118: 484–490 (2018)
DOI Google Scholar
[63]
Afshin E, Kadkhodayan M. An experimental investigation into the warm deep-drawing process on laminated sheets under various grain sizes. Mater Design 87: 25–35 (2015)
DOI Google Scholar
[64]
Kirkhorn L, Bushlya V, Andersson M, Ståhl J E. The influence of tool steel microstructure on friction in sheet metal forming. Wear 302(1–2): 1268–1278 (2013)
DOI Google Scholar
[65]
Meiler M, Jaschke H. Lubrication of aluminium sheet metal within the automotive industry. Adv Mater Res 6–8: 551–558 (2005)
DOI Google Scholar
[66]
Dyja K, Więckowski W. The effects of friction on stamping process of sheet metals used in aviation. Arch Metall Mater 60(3): 1895–1900 (2015)
DOI Google Scholar
[67]
Luo Y J, Wang R, He D N, Zhang Y Q. Determination of friction coefficient in sheet metal deep drawing. J Shanghai JiaoTong Univ 35(7): 969-971;969–971, 976 (2001) (in Chinese)
Google Scholar
[68]
Guo Z H, Li Z G, Huang C J, Dong X H. Research on the friction model for lubricated aluminium alloy sheet forming simulation. China Mech Eng 15(15): 1388–1391 (2004) (in Chinese)
Google Scholar
[69]
Recklin V, Dietrich F, Groche P. In-situ-measurement of the friction coefficient in the deep drawing process. J Phys Conf Ser 896: 012027 (2017)
DOI Google Scholar
[70]
Wang W R, Zhao Y Z, Wang Z M, Hua M, Wei X C. A study on variable friction model in sheet metal forming with advanced high strength steels. Tribol Int 93: 17–28 (2016)
DOI Google Scholar
[71]
Dong Y C, Zheng K L, Fernandez J, Li X Y, Dong H S, Lin J G. Experimental investigations on hot forming of AA6082 using advanced plasma nitrocarburised and CAPVD WC:C coated tools. J Mater Process Tech 240: 190–199 (2017)
DOI Google Scholar
[72]
Liewald M, Tovar G E M, Woerz C, Umlauf G. Tribological conditions using CO2 as volatile lubricant in dry metal forming. Int J Pr Eng Man-GT 7(5): 965–973 (2020)
DOI Google Scholar
[73]
Han S S. The influence of tool geometry on friction behavior in sheet metal forming. J Mater Process Tech 63(1–3): 129–133 (1997)
DOI Google Scholar
[74]
Kirkhorn L, Frogner K, Andersson M, Ståhl J E. Improved tribotesting for sheet metal forming. Procedia CIRP 3: 507–512 (2012)
DOI Google Scholar
[75]
Trzepieciński T, Lemu H G. Proposal for an experimental-numerical method for friction description in sheet metal forming. Stroj Vestn-J Mech E 61(6): 383–391 (2015)
DOI Google Scholar
[76]
Sanchez L R. Experimental investigation of friction effects enhanced by tool geometry and forming method on plane strain sheet metal forming. Tribol Trans 42(2): 343–352 (1999)
DOI Google Scholar
[77]
Fratini L, Casto S L, Valvo E L. A technical note on an experimental device to measure friction coefficient in sheet metal forming. J Mater Process Tech 172(1): 16–21 (2006)
DOI Google Scholar
[78]
Saha P K, Wilson W R D. Influence of plastic strain on friction in sheet metal forming. Wear 172(2): 167–173 (1994)
DOI Google Scholar
[79]
Bay N, Olsson D D, Andreasen J L. Lubricant test methods for sheet metal forming. Tribol Int 41(9–10): 844–853 (2008)
DOI Google Scholar
[80]
Andreasen J L, Olsson D D, Chodnikiewicz K, Bay N. Bending under tension test with direct friction measurement. P I Mech Eng B-J Eng 220(1): 73–80 (2006)
DOI Google Scholar
[81]
Ramezani M, Neitzert T, Pasang T, Sellès M A. Characterization of friction behaviour of AZ80 and ZE10 magnesium alloys under lubricated contact condition by strip draw and bend test. Int J Mach Tool Manu 85: 70–78 (2014)
DOI Google Scholar
[82]
Reichardt G, Liewald M. Investigation on friction behaviour of deep drawing radii using volatile media as lubricant substitutes. Procedia Manuf 29: 193–200 (2019)
DOI Google Scholar
[83]
Trzepiecinski T. A study of the coefficient of friction in steel sheets forming. Metals 9(9): 988 (2019)
DOI Google Scholar
[84]
Hao S, Klamecki B E, Ramalingam S. Friction measurement apparatus for sheet metal forming. Wear 224(1): 1–7 (1999)
DOI Google Scholar
[85]
Dilmec M, Arap M. Effect of geometrical and process parameters on coefficient of friction in deep drawing process at the flange and the radius regions. Int J Adv Manuf Tech 86(1): 747–759 (2016)
DOI Google Scholar
[86]
Evin E, Tomáš M. Tribology properties evaluation for friction pair Zn coated steel–TiCN MP coated/uncoated tool steel. Acta Metall Slovaca 25(4): 208–216 (2019)
DOI Google Scholar
[87]
Dou S S, Xia J S. Analysis of sheet metal forming (stamping process): A study of the variable friction coefficient on 5052 aluminium alloy. Metals 9(8): 853 (2019)
DOI Google Scholar
[88]
Klocke F, Trauth D, Shirobokov A, Mattfeld P. FE-analysis and in situ visualization of pressure-, slip-rate-, and temperature-dependent coefficients of friction for advanced sheet metal forming: Development of a novel coupled user subroutine for shell and continuum discretization. Int J Adv Manuf Tech 81(1): 397–410 (2015)
DOI Google Scholar
[89]
Zhou D, Yuan X, Gao H X, Wang A L, Liu J, El Fakir O, Politis D J, Wang L L, Lin J G. Knowledge based cloud FE simulation of sheet metal forming processes. J Vis Exp (118): 53957 (2016)
DOI Google Scholar
[90]
Tamai Y, Inazumi T, Manabe K I. FE forming analysis with nonlinear friction coefficient model considering contact pressure, sliding velocity and sliding length. J Mater Process Tech 227: 161–168 (2016)
DOI Google Scholar
[91]
Tabor D. Junction growth in metallic friction: The role of combined stresses and surface contamination. P Roy Soc A-Math Phy 251(1266): 378–393 (1959)
DOI Google Scholar
[92]
Leu D K. A simple dry friction model for metal forming process. J Mater Process Tech 209(5): 2361–2368 (2009)
DOI Google Scholar
[93]
Ramezani M, Ripin Z M. A friction model for dry contacts during metal-forming processes. Int J Adv Manuf Tech 51(1–4): 93–102 (2010)
DOI Google Scholar
[94]
Gearing B P, Moon H S, Anand L. A plasticity model for interface friction: Application to sheet metal forming. Int J Plasticity 17(2): 237–271 (2001)
DOI Google Scholar
[95]
Wilson W R D, Hsu T C, Huang X B. A realistic friction model for computer simulation of sheet metal forming processes. J Eng Ind 117(2): 202–209 (1995)
DOI Google Scholar
[96]
Darendeliler H, Akkök M, Ali Yücesoy C. Effect of variable friction coefficient on sheet metal drawing. Tribol Int 35(2): 97–104 (2002)
DOI Google Scholar
[97]
Yang T S. Investigation of the strain distribution with lubrication during the deep drawing process. Tribol Int 43(5–6): 1104–1112 (2010)
DOI Google Scholar
[98]
Başpınar M, Akkök M. Modeling and simulation of friction in deep drawing. J Tribol 138(2): 021104 (2016)
DOI Google Scholar
[99]
Sojoudi H, Khonsari M M. On the modeling of quasi-steady and unsteady dynamic friction in sliding lubricated line contact. J Tribol 132(1): 012101 (2010)
DOI Google Scholar
[100]
Zhao Y W, Maietta D M, Chang L. An asperity microcontact model incorporating the transition from elastic deformation to fully plastic flow. J Tribol 122(1): 86–93 (2000)
DOI Google Scholar
[101]
Karupannasamy D K, Hol J, de Rooij M B, Meinders T, Schipper D J. A friction model for loading and reloading effects in deep drawing processes. Wear 318(1–2): 27–39 (2014)
DOI Google Scholar
[102]
De Rooij M B, van der Linde G, Schipper D J. Modelling material transfer on a single asperity scale. Wear 307(1–2): 198–208 (2013)
DOI Google Scholar
[103]
Mishra T, de Rooij M, Shisode M, Hazrati J, Schipper D J. Analytical, numerical and experimental studies on ploughing behaviour in soft metallic coatings. Wear 448–449: 203219 (2020)
DOI Google Scholar
[104]
Mishra T, de Rooij M, Shisode M, Hazrati J, Schipper D J. Characterization of interfacial shear strength and its effect on ploughing behaviour in single-asperity sliding. Wear 436–437: 203042 (2019)
DOI Google Scholar
[105]
Mishra T, Ganzenmüller G C, de Rooij M, Shisode M, Hazrati J, Schipper D J. Modelling of ploughing in a single-asperity sliding contact using material point method. Wear 418–419: 180–190 (2019)
DOI Google Scholar
[106]
Mishra T, de Rooij M, Shisode M, Hazrati J, Schipper D J. An analytical model to study the effect of asperity geometry on forces in ploughing by an elliptical asperity. Tribol Int 137: 405–419 (2019)
DOI Google Scholar
[107]
Shisode M, Hazrati J, Mishra T, de Rooij M, ten Horn C, van Beeck J, van den Boogaard T. Modeling boundary friction of coated sheets in sheet metal forming. Tribol Int 153: 106554 (2021)
DOI Google Scholar
[108]
Hol J, Meinders V T, de Rooij M B, van den Boogaard A H. Multi-scale friction modeling for sheet metal forming: The boundary lubrication regime. Tribol Int 81: 112–128 (2015)
DOI Google Scholar
[109]
Mishra T, de Rooij M, Shisode M, Hazrati J, Schipper D J. A material point method based ploughing model to study the effect of asperity geometry on the ploughing behaviour of an elliptical asperity. Tribol Int 142: 106017 (2020)
DOI Google Scholar
[110]
Bowden F P, Moore A J W, Tabor D. The ploughing and adhesion of sliding metals. J Appl Phys 14(2): 80–91 (1943)
DOI Google Scholar
[111]
Challen J M, Oxley P L B. An explanation of the different regimes of friction and wear using asperity deformation models. Wear 53(2): 229–243 (1979)
DOI Google Scholar
[112]
Challen J M, Oxley P L B. Slip-line fields for explaining the mechanics of polishing and related processes. Int J Mech Sci 26(6–8): 403–418 (1984)
DOI Google Scholar
[113]
Hol J, Alfaro M V C, de Rooij M B, Meinders T. Advanced friction modeling for sheet metal forming. Wear 286–287: 66–78 (2012)
DOI Google Scholar
[114]
Karupannasamy D K, Hol J, de Rooij M B, Meinders T, Schipper D J. Modelling mixed lubrication for deep drawing processes. Wear 294–295: 296–304 (2012)
DOI Google Scholar
[115]
Greenwood J A, Williamson J B P. Contact of nominally flat surfaces. P Roy Soc A-Math Phy 295: 300–319 (1966)
DOI Google Scholar
[116]
Pullen B J, Williamson J B P. On the plastic contact of rough surfaces. P Roy Soc A-Math Phy 327: 159–173 (1972)
DOI Google Scholar
[117]
Westeneng A J D. Modelling of contact and friction in deep drawing processes. Ph.D. Thesis. Enschede (the Netherlands): University of Twente, 2001.
[118]
Hol J, Meinders V T, Geijselaers H J M, van den Boogaard A H. Multi-scale friction modeling for sheet metal forming: The mixed lubrication regime. Tribol Int 85: 10–25 (2015)
DOI Google Scholar
[119]
Venema J, Hazrati J, Atzema E, Matthews D, van den Boogaard T. Multiscale friction model for hot sheet metal forming. Friction 10(2): 316–334 (2022)
DOI Google Scholar
[120]
Venema J, Atzema E, Hazrati J, Matthews D, van den Boogaard T. Modelling of friction in hot stamping. Procedia Manuf 47: 596–601 (2020)
DOI Google Scholar
[121]
Shisode M, Hazrati J, Mishra T, de Rooij M, van den Boogaard T. Mixed lubrication friction model including surface texture effects for sheet metal forming. J Mater Process Tech 291: 117035 (2021)
DOI Google Scholar
[122]
Shisode M P, Hazrati J, Mishra T, de Rooij M, van den Boogaard T. Modeling mixed lubrication friction for sheet metal forming applications. Procedia Manuf 47: 586–590 (2020)
DOI Google Scholar
[123]
Nielsen C V, Martins P A F, Bay N. Modelling of real area of contact between tool and workpiece in metal forming processes including the influence of subsurface deformation. CIRP Ann 65(1): 261–264 (2016)
DOI Google Scholar
[124]
Kayaba T, Kato K. Experimental analysis of junction growth with a junction model. Wear 51(1): 105–116 (1978)
DOI Google Scholar
[125]
Lo S W, Tsai S D. Real-time observation of the evolution of contact area under boundary lubrication in sliding contact. J Tribol 124(2): 229–238 (2002)
DOI Google Scholar
[126]
Sutcliffe M P F. Surface asperity deformation in metal forming processes. Int J Mech Sci 30(11): 847–868 (1988)
DOI Google Scholar
[127]
Shisode M, Hazrati J, Mishra T, de Rooij M, van den Boogaard T. Evolution of real area of contact due to combined normal load and sub-surface straining in sheet metal. Friction 9(4): 840–855 (2021)
DOI Google Scholar
[128]
Bouchaâla K, Ghanameh M F, Faqir M, Mada M, Essadiqi E. Prediction of the impact of friction’s coefficient in cylindrical deep drawing for AA2090 Al–Li alloy using FEM and Taguchi approach. IOP Conf Ser Mater Sci Eng 664(1): 012004 (2019)
DOI Google Scholar
[129]
Shivpuri R, Zhang W F. Robust design of spatially distributed friction for reduced wrinkling and thinning failure in sheet drawing. Mater Design 30(6): 2043–2055 (2009)
DOI Google Scholar
[130]
Zabala A, de Argandoña E S, Cañizares D, Llavori I, Otegi N, Mendiguren J. Numerical study of advanced friction modelling for sheet metal forming: Influence of the die local roughness. Tribol Int 165: 107259 (2022)
DOI Google Scholar
[131]
Wiklund D, Rosén B G, Wihlborg A. A friction model evaluated with results from a bending-under-tension test. Tribol Int 42(10): 1448–1452 (2009)
DOI Google Scholar
[132]
Wiklund D, Larsson M. Phenomenological friction model in deep drawing of aluminium sheet metals. IOP Conf Ser Mater Sci Eng 418: 012097 (2018)
DOI Google Scholar
[133]
Bolay C, Essig P, Kaminsky C, Hol J, Naegele P, Schmidt R. Friction modelling in sheet metal forming simulations for aluminium body parts at Daimler AG. IOP Conf Ser Mater Sci Eng 651(1): 012104 (2019)
DOI Google Scholar
[134]
Durmaz U, Heibel S, Schweiker T, Merklein M, Berahmani S, Hol J, Naegele P. Enhancement of springback prediction of AHSS parts by advanced friction modelling. IOP Conf Ser Mater Sci Eng 1157(1): 012033 (2021)
DOI Google Scholar
[135]
Chezan A R, Khandeparkar T V, ten Horn C H L J, Sigvant M. Accurate sheet metal forming modeling for cost effective automotive part production. IOP Conf Ser Mater Sci Eng 651(1): 012007 (2019)
DOI Google Scholar
[136]
Güner A, Hol J, Venema J, Sigvant M, Dobrowolski F, Komodromos A, Tekkaya A E. Application of an advanced friction model in hot stamping simulations: A numerical and experimental investigation of an A-pillar reinforcement panel from Volvo cars. IOP Conf Ser: Mater Sci Eng 1157(1): 012020 (2021)
DOI Google Scholar
[137]
Sigvant M, Pilthammar J, Hol J, Wiebenga J H, Chezan T, Carleer B, van den Boogaard A H. Friction and lubrication modeling in sheet metal forming simulations of a Volvo XC90 inner door. IOP Conf Ser Mater Sci Eng 159: 012021 (2016)
DOI Google Scholar
[138]
Sigvant M, Pilthammar J, Hol J, Wiebenga J H, Chezan T, Carleer B, van den Boogaard A H. Friction in sheet metal forming: Forming simulations of dies in try-out. J Phys Conf Ser 1063: 012134 (2018)
DOI Google Scholar
[139]
Sigvant M, Pilthammar J, Hol J, Wiebenga J H, Chezan T, Carleer B, van den Boogaard A H. Friction in sheet metal forming simulations: Modelling of new sheet metal coatings and lubricants. IOP Conf Ser Mater Sci Eng 418: 012093 (2018)
DOI Google Scholar
[140]
Sigvant M, Pilthammar J, Hol J, Wiebenga J H, Chezan T, Carleer B, van den Boogaard T. Friction in sheet metal forming: Influence of surface roughness and strain rate on sheet metal forming simulation results. Procedia Manuf 29: 512–519 (2019)
DOI Google Scholar
[141]
Chezan T, Khandeparkar T, van Beeck J, Sigvant M. Strategies for increasing the accuracy of sheet metal forming finite element models. J Phys Conf Ser 1063: 012138 (2018)
DOI Google Scholar
[142]
Hol J, Wiebenga J H, Hörning M, Dietrich F, Dane C. Advanced friction simulation of standardized friction tests: A numerical and experimental demonstrator. J Phys Conf Ser 734: 032092 (2016)
DOI Google Scholar
[143]
Hol J, Wiebenga J H, Stock J, Wied J, Wiegand K, Carleer B. Improving stamping simulation accuracy by accounting for realistic friction and lubrication conditions: Application to the door-outer of the Mercedes-Benz C-class Coupé. J Phys Conf Ser 734: 032091 (2016)
DOI Google Scholar
[144]
Berahmani S, Bilgili C, Erol G, Hol J, Carleer B. The effect of friction and lubrication modelling in stamping simulations of the Ford Transit hood inner panel: A numerical and experimental study. IOP Conf Ser Mater Sci Eng 967: 012010 (2020)
DOI Google Scholar
[145]
Lacues J, Pan C, Franconville J C, Guillot P, Capellaere M, Chezan T, Hol J, Wiebenga J H, Souchet A, Ferragu V. Friction and lubrication in sheet metal forming simulations: Application to the Renault Talisman trunk lid inner part. IOP Conf Ser Mater Sci Eng 651(1): 012001 (2019)
DOI Google Scholar
[146]
Waanders D, Marangalou J H, Kott M, Gastebois S, Hol J. Temperature dependent friction modelling: The influence of temperature on product quality. Procedia Manuf 47: 535–540 (2020)
DOI Google Scholar
[147]
Van Beeck J, Chezan A R, Khandeparkar T V. Advanced tribomechanical modelling of sheet metal forming for the automotive industry. IOP Conf Ser Mater Sci Eng 418: 012096 (2018)
DOI Google Scholar
[148]
Ghiotti A, Bruschi S, Medea F. Wear onset in hot stamping of aluminium alloy sheets. Wear 376–377(A): 484–495 (2017)
DOI Google Scholar
[149]
Kamis S L, Lah M A C, Rahama N S, Abd Rahim N A. Fabrication and tribological characterization of aluminium alloy by using photochemical machining. Jurnal Tribologi 28: 82–95 (2021)
Google Scholar
[150]
Taha-Tijerina J J, Garza G T, Maldonado-Cortés D. Evaluation of parameters for application of Laser Surface Texturing (LST) in tooling for the sheet-metal forming process. Ind Lubr Tribol 70(4): 620–627 (2018)
DOI Google Scholar
[151]
Costa H L, Hutchings I M. Some innovative surface texturing techniques for tribological purposes. P I Mech Eng J-J Eng 229(4): 429–448 (2015)
DOI Google Scholar
[152]
Gachot C, Rosenkranz A, Hsu S M, Costa H L. A critical assessment of surface texturing for friction and wear improvement. Wear 372–373: 21–41 (2017)
DOI Google Scholar
[153]
Flegler F, Neuhäuser S, Groche P. Influence of sheet metal texture on the adhesive wear and friction behaviour of EN AW-5083 aluminium under dry and starved lubrication. Tribol Int 141: 105956 (2020)
DOI Google Scholar
[154]
Hu T C, Hu L T. The study of tribological properties of laser-textured surface of 2024 aluminium alloy under boundary lubrication. Lubr Sci 24(2): 84–93 (2012)
DOI Google Scholar
[155]
Murakawa M, Koga N, Kumagai T. Deep-drawing of aluminium sheets without lubricant by use of diamond-like carbon coated dies. Surf Coat Tech 76–77: 553–558 (1995)
DOI Google Scholar
[156]
Sgarabotto F, Ghiotti A, Bruschi S. Influence of temperature on AA6014 alloy tribological behaviour in stamping operations. AIP Conf Proc 1353(1): 1723–1728 (2011)
DOI Google Scholar
[157]
Häfner T, Rothammer B, Tenner J, Krachenfels K, Merklein M, Tremmel S, Schmidt M. Adaption of tribological behavior of a-C:H coatings for application in dry deep drawing. MATEC Web Conf 190: 14002 (2018)
DOI Google Scholar
[158]
Krachenfels K, Rothammer B, Tremmel S, Merklein M. Experimental investigation of tool-sided surface modifications for dry deep drawing processes at the tool radii area. Procedia Manuf 29: 201–208 (2019)
DOI Google Scholar
[159]
Cai H L, Zhang C, Li H T, Jiang B L. Self-lubricating nanocomposite coatings using MAO to improve tribological properties of 6061 aluminium alloy. Mater Res Express 8(3): 036401 (2021)
DOI Google Scholar
[160]
Dong Y C, Zheng K L, Fernandez J, Fuentes G, Li X Y, Dong H S. Tribology and hot forming performance of self-lubricious NC/NiBN and NC/WC:C hybrid composite coatings for hot forming die. J Mater Process Tech 252: 183–190 (2018)
DOI Google Scholar
[161]
Lacki P. Optimisation of the stamping processes for a drawn-part made of aluminium. Key Eng Mater 410–411: 271–278 (2009)
DOI Google Scholar
[162]
Maldonado-Cortés D, Peña-Parás L, Barrios-Saldaña V, Cruz-Bañuelos J S, Adamiak M. Synergistic effect on the tribological properties of tool steel through the use of laser surface texturing channels and nanoparticles. Wear 426–427(B): 1354–1361 (2019)
DOI Google Scholar
[163]
Tenner J, Zhao R, Tremmel S, Häfner T, Schmidt M, Merklein M. Tribological behavior of carbon based coatings adapted to lubricant-free forming conditions. Int J Pr Eng Man-GT 5(3): 361–367 (2018)
DOI Google Scholar
[164]
Tillmann W, Stangier D, Lopes-Dias N F, Biermann D, Krebs E. Adjustment of friction by duplex-treated, bionic structures for Sheet–Bulk Metal Forming. Tribol Int 111: 9–17 (2017)
DOI Google Scholar
Publication history
Copyright
Acknowledgements
Rights and permissions

Publication history

Received: 11 February 2022
Revised: 22 August 2022
Accepted: 21 March 2023
Published: 04 July 2023
Issue date: March 2024

Copyright

© The author(s) 2023.

Acknowledgements

The authors greatly appreciate the financial support by the National Natural Science Foundation of China (11502044, U1906233, and 52175289), the Fundamental Research Funds for the Central Universities (DUT17RC (3)104), and the National Key R&D Program of China (2018YFA0703 and 2019YFA0708804). We also thank Professor Shijian YUAN and Professor Jun YAN, working at Dalian University of Technology, China, for useful discussions and suggestions.

Rights and permissions

Open Access This article is licensed under a Creative Commons Attribution 4.0 International License, which permits use, sharing, adaptation, distribution and reproduction in any medium or format, as long as you give appropriate credit to the original author(s) and the source, provide a link to the Creative Commons licence, and indicate if changes were made.

The images or other third party material in this article are included in the article’s Creative Commons licence, unless indicated otherwise in a credit line to the material. If material is not included in the article’s Creative Commons licence and your intended use is not permitted by statutory regulation or exceeds the permitted use, you will need to obtain permission directly from the copyright holder.

To view a copy of this licence, visit http://creativecommons.org/licenses/by/4.0/.

Return