Contact pressure evolution and its relation to wear in sheet metal forming

Pereira, Michael P., Yan, Wenyi and Rolfe, Bernard F. 2008, Contact pressure evolution and its relation to wear in sheet metal forming, Wear, vol. 265, no. 11-12, pp. 1687-1699, doi: 10.1016/j.wear.2008.04.042.

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Title Contact pressure evolution and its relation to wear in sheet metal forming
Author(s) Pereira, Michael P.ORCID iD for Pereira, Michael P.
Yan, Wenyi
Rolfe, Bernard F.ORCID iD for Rolfe, Bernard F.
Journal name Wear
Volume number 265
Issue number 11-12
Start page 1687
End page 1699
Total pages 13
Publisher Elsevier B.V.
Place of publication Amsterdam, The Netherlands
Publication date 2008-11-26
ISSN 0043-1648
Keyword(s) contact pressure
finite element analysis
sheet metal forming
Summary For a given sheet metal forming process, an accurate determination of the contact pressure distribution is an essential step towards the estimation of tool life. This investigation utilizes finite element (FE) analysis to model and explain the evolution and distribution of contact pressure over the die radius, throughout the duration of a channel forming process. It was found that a typical two-peak steady-state contact pressure response exists for the majority of the process. However, this was preceded by an initial transient response, characterized by extremely large and localized contact pressures, which were more than double the magnitude of the steady-state peak pressure. The validity of the predicted contact pressure behavior was assessed via detailed numerical analysis and by examining the wear response of an experimental stamping operation. The experimental results revealed that the high contact pressure zones of the transient response corresponded to a severe galling wear mechanism. Therefore, the transient response may be of primary significance to the tool wear response; thus questioning the applicability of traditional bending-under-tension wear tests for sheet metal stamping processes. Finally, a parametric study was conducted, examining the influence of the major process parameters on the steady-state and peak transient contact pressures, using the developed FE model. It was found that the bend ratio and the blank material ultimate tensile strength had the most influence on the peak contact pressures. The main process-related parameters, friction coefficient and blank holder force, were found to have only a minor influence.
Language eng
DOI 10.1016/j.wear.2008.04.042
Field of Research 091399 Mechanical Engineering not elsewhere classified
Socio Economic Objective 970109 Expanding Knowledge in Engineering
HERDC Research category C1 Refereed article in a scholarly journal
Copyright notice ©2008, Elsevier B.V.
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Document type: Journal Article
Collections: Centre for Material and Fibre Innovation
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