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
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
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DOI：
10.1007/s00170-015-7184-1
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发表时间：
2015-10-01
影响因子：
3.4
通讯作者：
Mattfeld, P.
中科院分区：
文献类型：
--
作者：
Klocke, F.;Trauth, D.;Mattfeld, P.
在金属板料成形有限元模拟中，库仑摩擦系数通常被假定为整个工具区域的常数。最近的研究表明，在典型的金属板成形的接触条件下，摩擦系数强烈地依赖于相互作用的伙伴之间的接触压力和滑移率以及接触温度。本文提出了一种基于Filzek方法的摩擦定律，并在Abaqus中作为用户子程序实现。此外，一个新的用户子程序耦合的开发，使每个接触节点的局部摩擦系数的可视化。这是第一次使用有限元系统Abaqus在板材成形模拟中实现局部摩擦系数的现场可视化。多种评估算法，以及。利用工业拉深过程的实验数据对所提出的摩擦模型和用户子程序耦合进行了验证。摩擦建模和摩擦系数的原位可视化的建议相结合，使摩擦热点的识别。基于这样的分析，工具和模具制造业可以通过在低摩擦或高摩擦区域应用特殊涂层，或通过选择不同的工具插入物材料，或通过改变润滑剂的类型和量来实现摩擦学优化的工具。而所提出的摩擦模型是定制的金属板材成形和开发使用的商业代码Abaqus，可视化耦合方法是可转移到任何制造过程和支持Fortran编程语言的各种FE系统。
In sheet metal forming simulations using finite element method, the coefficient of friction according to Coulomb is normally assumed to be constant for the whole tool region. Recent research has demonstrated that under contact conditions typical for sheet metal forming, the coefficient of friction is strongly dependent on the contact pressure and the slip-rate between the interacting partners as well as on the contact temperature. A friction law based on the approach of Filzek is proposed in this research paper and implemented as a user subroutine in Abaqus. Moreover, a novel user subroutine coupling is developed which enables the visualization of local coefficients of friction for every contact node. For the very first time, this enables the in situ visualization of local coefficients of friction in sheet metal forming simulations using the FE system Abaqus. Multiple evaluation algorithms are presented as well. The presented friction model and the user subroutine coupling are validated using experimental data of an industrial deep drawing process. The proposed combination of the friction modeling and the in situ visualization of coefficients of friction enables the identification of friction hot spots. Based on such analysis, the tool and die making industry can realize tribologically optimized tools either by applying special coatings in areas of low or high friction, or by choosing different materials for tooling inserts, or by changing the type as well as the amount of the lubricant. Whereas the presented friction model is tailored to sheet metal forming and developed using the commercial code of Abaqus, the visualization coupling methodology is transferable to any manufacturing process and various FE systems supporting Fortran programming language.