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Measurement of friction under sheet forming conditions

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Abstract

Among the tests used to evaluate friction in sheet forming processes, bending-under-tension (BUT) tests have received considerable attention. A new test was developed incorporating a smooth increase of wrap angle during deformation, even at high deformation rates, thus replicating typical conditions at die radii. A corresponding data analysis procedure was introduced to separate the effects of bending and friction and to account for the strain-rate sensitivity of the test material. The new test and analytical procedure were used to investigate the frictional behavior for four sheet alloys: interstitialfree (IF) steel, high-strength galvanized (HSG) steel, 2008-T4 aluminum, and 70/30 brass. A range of testing rates, pin radii, and lubrication conditions were employed, and the variation of friction coefficient (μ) as a function of contact radius, contact angle, and punch speed was measured. Complex variations ofμ with respect to tool radius and wrap angle were observed, consistent with previous studies. No significant, systematic variation ofμ was found for punch speeds ranging from 1.7 to 170 mm/s, contrary to reports in the literature. Failures in 2008-T4 aluminum shifted from tensile localization to bending as the tool radius was reduced. The other materials consistently failed by tensile localization.

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Author notes

  1. W. Wang (Graduate Student, Project Engineer)

    Present address: the Department of Materials Science and Engineering, The Ohio State University, 43210-1179, Columbus, OH

Authors and Affiliations

  1. Research and Development Division, Inland Steel, 46212, East Chicago, IN

    W. Wang (Graduate Student, Project Engineer)

  2. the Department of Materials Science and Engineering, The Ohio State University, 43210-1179, Columbus, OH

    R. H. Wagoner (Professor)

  3. the Department of Metal Forming, University of Science and Technology Beijing, 100 083, Beijing, People’s Republic of China

    X. -J. Wang (Professor and Chair)

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  2. R. H. Wagoner
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  3. X. -J. Wang
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Wang, W., Wagoner, R.H. & Wang, X.J. Measurement of friction under sheet forming conditions. Metall Mater Trans A 27, 3971–3981 (1996). https://doi.org/10.1007/BF02595646

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