Identification of parameters for complex friction models in hot bulk metal forming by an extension of the conical tube upsetting test

金属成形过程中的摩擦会影响材料的流动和必要的成形力。在设计工具和工艺时，应考虑摩擦力。这一点在现代模拟技术中尤其适用，如有限元方法。除了经典的库仑模型和摩擦因数模型外，还存在大量具有多个摩擦参数的复杂摩擦模型。这些现代摩擦模型考虑了摩擦条件的不同影响因素。经典摩擦模型可以在实验室规模的不同代表性实验(如环压缩实验)中进行参数化。通常，对于现代摩擦模型，多个摩擦参数是通过比较实际成形过程和模拟过程来拟合的。在该项目的第一阶段，使用模拟试验(锥形管镦粗试验)的反向模拟来开发一种允许多参数摩擦模型的参数化的方法。使用库仑模型可以看出，所提出的方法在原理上是可行的，并且对其他输入参数的波动具有高度的稳健性。之后，该方法可以成功地转移到多参数摩擦模型。结果表明，对于复杂的摩擦模型，没有普遍有效的策略。相反，根据模型和模型中考虑的参数，不同的工艺条件或建模策略会导致成功。因此，本继续提案的目的是进一步发展项目过程中迄今开发的建模策略，使现代摩擦模型的参数可以通过使用稳健的方法进行反向建模来实现对热块金属成形过程中发生的工艺参数的现代摩擦模型参数的一致确定。到目前为止所取得的结果清楚地表明，对于多参数模型，不存在普遍有效的解，并且需要相应的工艺窗口，以便为所用摩擦模型的明确参数化提供充分的数据基础。因此，下一步是使用热的块状金属成形过程的典型工艺窗口。相对速度和法向应力的发生过程窗口应通过强烈摩擦影响的示例性过程确定，并转移到圆锥管的顶粗试验中。随后，为每个所考虑的模型开发最优建模策略，以便最终将其应用于实验结果，并通过示例性过程来执行所确定的参数的验证。随着该项目的完成，热金属块状成形复杂摩擦模型的可靠测试和可靠的方法就可用了。

Friction in metal forming processes influences material flow and necessary forming forces. For the design of tools and processes friction should be considered. This holds especially within modern simulation techniques like the Finite Element Method (FEM). Beside of the classical Coulomb and friction factor model a significant number of complex friction models with multiple friction parameters exists for hot bulk metal forming. These modern friction models allow for consideration of different influencing factors on the friction conditions. A parametrization of classical friction models can be done in different representative experiments in laboratory scale (e.g. ring compression test). Usually, for modern friction models the multiple friction parameters are fitted by comparison between the real forming process and a simulation.In the first phase of the project, an inverse modelling of an analogy test (conical tube-upsetting test) was used to develop a methodology that allows for the parameterisation of multi-parametric friction models. Using the Coulomb model, it could be shown that the developed methodology works in principle and has a high degree of robustness against fluctuations of other input parameters. Afterwards, the methodology could be successfully transferred to multi-parametric friction models. The results showed that there is no generally valid strategy for complex friction models. Rather, depending on the model and the parameters considered in it, different process conditions or modelling strategies lead to success.The aim of this continuation proposal is therefore to further develop the modelling strategy developed in the course of the project to date in such a way that a consistent determination of the parameters of modern friction models for the process parameters occurring in hot bulk metal forming processes can be achieved by inverse modelling with robust methods. The results achieved so far clearly show that there is no generally valid solution for multi-parametric models and that a corresponding process window is needed in order to have a sufficient data basis for the definite parameterization of the friction models used. The next step is therefore to use typical process windows of a hot bulk metal forming process. The occurring process windows for relative velocities and normal stresses shall be determined by means of a strongly friction influenced example process and transferred to the conical tube-upsetting test. Subsequently, an optimal modelling strategy is developed for each of the considered models in order to finally apply it to experimental results and to perform a validation of the determined parameters by means of an exemplary process. With the completion of the project a robust test and a secured methodology for the parameterization of complex friction models for hot bulk metal forming is available.