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Tribological Aspects of Numerical Simulation

of Deep-Drawing Process
Jozef Vyboch, Emil Evin, Jozef Kmec
Abstract
In this contribution the results obtained by FEM simulation and experiments are compared. Values of friction
coefficients were experimentally obtained by cup test at change of blankholder pressure and size of blank.
Keywords: formability, FEM simulation, cup test, friction coefficient

1 Introduction
Formability of steel sheets (produceability of stamped
part) depends on material properties (mechanical properties,
microgeometry of contact surfaces), geometry of die and
microgeometry of its contact surfaces, pressure of blankholder, used lubricant, etc. By changing material properties
the change of formability approx. 10-15 % can be obtained,
by changing die geometry about 30-35 %, by changing
friction ratios approx. about 35 %, and other effects can be
obtained by changing sheet thickness, strain speed, etc. 1.
Accurate determination of influence of single parameters on
technological characteristics is problematic, because single
parameters are changed from one case to another and also
their share on formability is changed. To predict the influence of material properties, geometry of die, stamping conditions on sheet formability is possible by simulation methods which enable us to optimise the utilisation of material
properties under concrete conditions. The result of simulation depends on:
- used material model,
- accuracy and completness of simulation software,
- accuracy and completness of material database,
- accuracy and completness of tribological data etc.
(e.g. restricting conditions).
Specialized CAE softwares for simulation of sheet
metal forming processes use the explicit formulation of
FEM for solution of motion equation of equilibrium they
consider non-linear deformation history of sheet and for
description of material behaviour the Hills condition of
plasticity is used :
f
2
r90 . 112 r0 . 22
r90 .r0 . 11 22 2.r45 1
. r90 r0 . 122
2

(1)

r90 .r0 1

where:
r0, r90, r45 are the values of normal anisotropy coefficients
due to rolling direction.
Hardening of material is described by the SwiftKrupkowskys relation. Understanding the deformation history enables us to include the criteria of material damage
(thinning, curve of limiting deformation), creation of wrinkling, pressure on contact surfaces, drawig forces, etc. into
calculation.
By changing friction ratios of material couple sheet
stamping die, the change of material flow can be expessively influenced in such range that the sheet which on the
basis of values of mechanical properties shows unsuitability
to production of concrete stamped part, at application of
suitable lubricant shows required formability in some cases

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i.e. it is suitable for production of concrete stamped part.


And on the contrary, the material with excellent forming
properties and unsuitable surface microgeometry at application of unsuitable lubricant may be in some cases
unsuitable for production of given stamped part (it shows
lower formability). At formability prediction it is important
to define the friction ratios in die value of friction coefficient. Requirement for completness of information on
friction ratios has arisen from the moment when for
prediction of formability the simulation methods, new high
strength materials, materials with various surface treatment
started to be used. Tribological properties of these materials
are different from those classical intended for deep drawing.
It means, that what is suitable for classical steel sheets need
not be suitable for sheets with applicated surface treatmentfig.1.

Fig. 1 C-E analysis of the tribological processes


Lubricants for deep drawing are selected according to
combination of materials of friction couples, according to
surface microgeometry of contact surfaces, size of stressing
of contact surfaces and not at last measure according to
influence on working environment and possibilities of their
application and degreasing. Requirements on function of
lubricants applied at stamping are contrary in many cases,
however in the greater amount of cases the aim is decreeasing the friction, providing the quality of surface of both
the formed part and die and influencing the flow of material
by friction.
Database of lubricants for deep drawing should contain
information on friction coefficients for various combinations of material couples, stressing, and drawing speed. In
stamping processes the mixed friction occurs the most frequently. To restrict the rise of dry friction the lubricants
with surface active substances (polar effective substances,
high-pressure substances - EP-additives) are used which
then provide adsorption and chemisorption. At incre-asing
the pressure on contact surfaces in consequence of acting of

additives the value of friction coefficient is constant or in


some cases the decrease of friction coefficient values
occurs.
Lubricity can be non-directly evaluated on the basis of
dynamic and kinematic viscosity. For instance, the Burns
equation describes the dependance of dynamic viscosity on
pressure and temperature as follows:

0 .e

. p . T

(2)

where:
0 - reference dynamic viscosity determined at
reference temperature,
- coefficient in dependance on pressure,
- coefficient in dependance on temperature,
p - pressure on contact surfaces,
T - difference between working and reference
temperatures.
Despite the great amount of various research works, for
the state of mixed friction, the dependance of friction coefficient on lubricant properties and stamping conditions has
not been physically described yet. For determination of
friction coefficient for various lubricants and surfaces the
model equipment is used simulators or technological tests
that simulate the stressing of material in real stamping process.

ces of friction coefficient on pressure of jaws were descrybed by following regression models:
material B lubricant FERROCOAT

f B a 0 B . p 0 , 2

(3)

material E lubricant FERROCOAT

f E a 0 E . p 0,192

(4)

Pressure of jaws was modeled in the range 1,5 MPa to


10 MPa.
For instance at pressure of jaws p = 2 MPa value of friction coefficient at material B was fB = 0,131 and at material
E was fE= 0,146.
Drawing conditions for cylindrical cup are given in Tab.
2. Friction coefficient in this case was determined by:
a) methodics based on the change of blankholder pressure at constant blank diameter (Fig. 2):

2 Used methods and obtained results


In the framework of national projects VEGA and
international project ENFORM the research for determination of friction coefficient by various methods was carried
out. For verification of the programme file PAM-STAMP
applied for simulation of sheet metal forming processes the
drawing force was used as a criterion because it sensitively
reacts on the change of friction ratios at deep drawing. Drawing forces determined by simulation were compared with
results obtained in deep-drawing process of cylindrical cups
made of deep-drawable steel sheet B (type DC05) and zinccoated sheet E Tab. 1. Used lubricant FERROCOAT A
6130 is the mixture of mineral oils, synthetic esters and
additives with kinematic viscosity 26 mm2 /s at temperature
40o C.

Rp0,2
[MPa]

Rm
[MPa]

C
[MPa]

Rolling
direction

Material

Tab. 1 Material properties of tested materials

164

299

505

45

172

309

531

0,006

0,23

1,9

0,219

1,5

0,221

2,2

90

166

296

511

168

303

531

0,228

170

292

492

0,208

1,98

45

180

304

503

0,203

1,04

90

184

297

487

0,215

1,59

182

300

497

0,008

0,207

X mean value
For determination of friction coefficient the tester with
parallel jaws and drawing die for cylindrical cups were
used.
On the basis of obtained results by tester the dependan-

Fig. 2 Dependence of drawing force on blankholding force

Ft 2 Ft1
2.( F p 2 F p1 )

(5)

This relation was determined from condition of equilibrium of forces acting in deep drawing process and also at
the assumption that friction coefficient on contact surfaces
between sheet, blankholder and die is not changed (f1 = f2 =
f3), angle of wrap of the die drawing edge in the moment
of drawing force maximum is equal = /2. Measured values of friction coefficients are given in Fig. 2 and Tab. 3.
Tab. 2 Conditions of experiment
Material of die
Material of blankholder
Material of punch
Diameter of punch with
flat bottom
Radius of die edge of
punch with flat bottom
Radius of die edge of die
Clearance - flat bottom
Sheet metal thickness
Roughness of punch with
flat bottom
Roughness of die
Amount of lubricant

19 732 die steel according to


Slovak Standard
12 061
19 732
32,85 mm
4,5 mm
4,5 mm
1,57 mm
0,8 mm
Ra = 0.8 m
Ra = 0.4 m
7g/m2

Tab. 3 Calculated values of friction coefficients


Material
B
E

Drawing force
[kN]
Ft1
Ft2
22,4
24
20,5
22,5

Blankholding
force [kN]
Fp1
Fp2
2
10
2
10

Friction
coefficient f
0,104
0,127

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b) methodics based on comparing the drawing force determined at utilisation of reference lubricant Ftrto drawing
force Ftij determined at utilisation of tested lubricant [1]:

ij

Fij
Ftrj

(6)

From the equilibrium condition of forces it is possible to


express the increment of friction due to reference lubricant:

f ij

ij 1
1,16 k

speed at materials type DC 05 can be described by dependance of real stress on deformation speed by equation

C. 0, 0695 , then at the speed change from 0,0008 s-1


to 0,3 s-1 the increase of strengthness about approx. 40 60
MPa occurs. Programme product PAM-STAMP enables us
to include into calculation the influence of deformation
speed. Taking into account the influence of deformation
speed the differences between measured and calculated
values approx. 5 % may be expected.

(7)

where:
k = Fpij / Ftij
Fpij blankholding force,
Ftij drawing force,
Ftrj drawing force at application of reference
lubricant,
i lubricant,
j material.
Then the final friction coefficient is:

f ij f rj f ij

(8)

Drawing forces were determined at drawing of


cylindrical cup with blank diameter D01=60, D02=65 and
D03=70 mm. Course of drawing force determined by
simulation of cylindrical cup made of material B and blank
D01=60 mm is given in Fig. 2. Calculated and measured
values od drawing forces at drawing of cups made of
materials B, E are given in Tab. 4.
From Fig. 3 and Fig.5 result that dependances determined on the basis of experimental results and obtained by
simulation show a very good correlation
of tendencies of dependances (slopes).

Fig. 4 Dependance of drawing force on blank diameter


EN-measured values, ES-calculated values

Fig. 5 Dependance of drawing force on blank diameter


EN-measured values, ES-calculated values

3 Summary

Fig. 3 Course of drawing force versus time - material B,


blank diameter D01 = 60 mm
Difference between measured and calculated values can
be due to the fact that material properties were obtained at
strain speed 0,0008 s-1 and drawing was carried out at strain
speed 0,3 s-1. According to 2 if influence of deformation

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From measured results there can be stated:


1. Difference between measured and calculated values of
drawing forces is approx. 20 % without including the
influence of deformation speed. Measured values of drawing forces in comparison to values obtained by simulation were higher.
2. Obtained results show that programme product PAMSTAMP enables us to simulate the influence of parameters of deep drawing process with acceptable accuracy,
however it is required countinuously to make more accurate the input material and technological data.
3. Obtained results show also the fact that by combination
of both the simple tester tests and technological tests the
values of friction coefficients for various combinations
of stamping conditions can be determined, however it is
necessary to define the accurate conditions of experiment.

4. PAM-STAMP enables us to predict the pressure on


contact surfaces between die and sheet and by this the
optimisation of experiment conditions may be carried
out, and also the selection of suitable lubricant for
concrete technological process.

References

[1] Lange.K.: Umformtechnik. Blechbearbeitung. Springer


/Ferlag 1990
[2] Kuzman,K. et al.: Environmental friendly lubricants in
deep drawing of steel sheet metal. Report for the period January 1999 January 2000 Celje 2000.
Acknowledgement
[3] Pvek,L.-Prantl,A.: PAM-STAMP - Prklady - Nov
This article was created by implementation of the protrendy ve vrob vlisku z plechu. Praha, 1999.
ject "Centre for Management Research technical, environ- [4] Evin,E.: Tvrnitenos vysokopevnch ocel a ich premental and human risks for sustainable production and propredikcia. Habilitan prca. SjF TU Koice, 1996.
ducts in engineering" (ITMS: 26220120060), by supporting [5] imk,F.-Kokarda,V.-Holl,A.-Kraj,J.: Niektor
operational program Research and development program
charakteristiky lisovatenosti lbokoanch plechov
financed from the European Regional Development Fund.
produkcie VS a.s.Oceov plechy 3-4/1993.
The authors the work gratefully acknowledge for the [6] Labellarte,A.-Rizzo,L.-Sebastiani,C.:High Strain Rate
financial support of the Scientific Grant Agency of the
Forming Limiting Diagram for Steel and Titankium
Slovak Republic (VEGA 10890/09).
with an Optimised Metodology. IDDRG-working grup
3, USA, 2000.
[7] Hrivk, A. et al: tdium tribologickch pomerov v
procese lisovania. Projekt VEGA (1/6194/99), Koice,
Vyboch Jozef, M.Sc.,
2002
Faculty of Mechanical Engineering
of the Technical University of Kosice, [8] Evin, E. et al: Optimalizcia vroby vliskov z vysokopevnch oceovch plechov. Projekt VEGA (1/7637
Msiarsk 74, 040 01 Kosice,
/20), Koice,2002
Slovak Republic
E-mail: jozef.vyboch@tuke.sk [9] ada,R.: Tvitelnost ocelovch plechu. REPRONIS
Ostrava 2001
Prof. Evin Emil, M.Sc., PhD.,
[10 [10] Kmec, J. - Evin, E.: Precdicted Model of Stampability
Faculty of Mechanical Engineering
of Steeel Sheet Metal with Higher Strength Properties.
of the Technical University of Kosice,
Manufacturing Engineering/Vrobn ininierstvo,
Msiarsk 74, 040 01 Kosice,
FVT TU Presov, Nr. 3, 2010, Volume IX, pp 55-57.
Slovak Republic
E-mail: emil.evin@tuke.sk
Kmec Jozef, RNDr., PhD.,
Faculty of Manufacturing Technologies of the
Technical University of Kosice with a seat in Presov,
Bayerova 1, 080 01 Presov,
Slovak Republic
E-mail: jozef.kmec@tuke.sk

Continued from page 37

Acknowledgement
Presented results have been obtained within research
project, realized in years 2009-2011, financially supported
by Polish Ministry of Science.
Prof. Zbala Wojciech, M.Sc., Dr hab.,
Cracow University of Technology,
Faculty of Mechanical Engineering,
Production Engineering Institute,
Department of Machining and Processes,
al. Jana Pawa II 37, 31-864 Krakw,
Poland,
zebala@mech.pk.edu.pl,

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