A methodology based on finite element computations is proposed to predict the galling onset of aluminium alloys in cold forming. The methodology assumes that galling starts as soon as a finite element in the area of contact has reached a critical damage. The damage is calculated using Xue's model, which takes into account the effect of tangential stresses on the damage evolution. The tangential stress is calculated using Wilson's mixed lubrication model taking into account the roughness of the tools. Strip reduction tests were performed on aluminium AA6082 specimens, with and without lubricant. The proposed numerical model is in good agreement with experiments and is able to predict the onset of galling. The model is sufficiently accurate to determine the effect of tool roughness.

提出了一种基于有限元计算的方法来预测铝合金在冷成型过程中的磨损开始。该方法假设一旦接触区域中的有限元达到临界损坏，磨损就会开始。使用 Xue 的模型计算损伤，该模型考虑了切向应力对损伤演化的影响。切向应力是使用威尔逊的混合润滑模型计算的，同时考虑了工具的粗糙度。对 AA6082 铝试样进行带材减少测试，使用和不使用润滑剂。所提出的数值模型与实验非常吻合，并且能够预测磨损的开始。该模型足够精确，可以确定刀具粗糙度的影响。