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A Review on Friction and Lubrication in Automotive Metal Forming: Experiment and Modeling

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Abstract

Metal forming or shaping processes, such as sheet metal forming and bulk forming, are widely used in many industries including automotive industry. Before computational simulations were widely used in the field of metal forming industry, the trial-and-error based empirical approach was conventionally applied to the optimization of the metal forming process and product. The most commonly employed numerical approach in the metal forming process for robust process optimization is the finite element analysis. Friction, one of the parameters that significantly affect the accuracy of numerical analysis, depends on several variants such as surface quality, contact pressure, lubrication, deformation, and the forming environment. Despite the complexity and difficulty of identifying friction mechanisms, accurate friction models are essential and hence have been proposed by numerous researchers. In this paper, the friction models in the previous studies are reviewed by categorizing them into the boundary lubrication condition and mixed-boundary lubrication condition according to their evaluative influences on friction. Since friction models have been proposed based on the contact theories, an overview on the contact models is also included in this paper. In addition, the contribution of several parameters on the friction such as surface roughness and material properties of the tool, adhesion, contact pressure, sliding speed, bulk deformation is also discussed. This review paper aims to provide an understanding and insight into the friction modeling and simulation along with associated friction experiments.

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Abbreviations

a:

major axis of ellipse, m

b:

minor axis of ellipse, m

AR :

real contact area, m2

A’:

crosssection of torn track, m2

AN :

nominal contact area, m2

d:

distance between the workpiece asperities and the tool, m

F:

friction force, N

Fb :

back-tension force, N

FN :

normal force, N

FP :

pulling force, N

fc :

shear factor

h:

film thickness, m

H:

hardness, Pa

Heff :

non-dimensional effective hardness, Pa

k:

shear strength of material, Pa

p:

plastic yield stress (Flow pressure), Pa

p0 :

initial plastic yield stress, Pa

pnom :

nominal contact pressure, Pa

plub :

hydrodynamic pressure, Pa

R:

radius of summits, m

s:

shear stress of metal junctions, Pa

Sq :

standard deviations of combined roughness, m

t:

time, s

v:

sliding velocity, m/s

v1 :

velocity in x and y direction at the lower surface, m/s

v2 :

velocity in x and y direction at the lower surface, m/s

w:

indentation depth of elliptical paraboloid, mm

x, y, z:

direction

α:

fractional real contact area

β:

effective attack angle

φ:

orientation angle

Φ:

surface height distribution, m−1

Φp :

pressure flow factor (Second order tensor)

Φs :

shear flow factor (Second order tensor)

γ:

surface orientation characteristic

η:

viscosity of lubricant, Pa·s

λ0.5x :

correction length of surface profile in x direction, m

λ0.5y :

correction length of surface profile in y direction, m

μ:

friction coefficient

θ:

hard asperity attack angle

ρ:

density of lubricant, kg/m3

σ:

standard deviation of roughness (root mean square of roughness), m

τ:

shear strength of boundary film, Pa

τlub :

hydrodynamic Shear strength, Pa

ω:

interference, m

ω1 :

critical interference at the point of initial yield, m

ω2 :

critical interference at the point of fully plastic flow, m

cutting:

cutting mode

lub:

lubricant

nom:

nominal

N:

normal direction

plowing:

plowing mode

wear:

wear mode

x, y, z:

axis

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Acknowledgement

MGL appreciates partial supports from National Research Foundation (NRF) of Korea (Grant No. 2019R1A5A6099595) and from KEIT (Project No. 20010453). Also, MGL & CMM thank the partial support from KEIT (No. 20010717) for investigating the effect of friction on forming.

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  1. Department of Materials Science and Engineering and RIAM, Seoul National University, Seoul, 08826, Korea

    Kijung Lee, Chanmi Moon & Myoung-Gyu Lee

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  1. Kijung Lee
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Lee, K., Moon, C. & Lee, MG. A Review on Friction and Lubrication in Automotive Metal Forming: Experiment and Modeling. Int.J Automot. Technol. 22, 1743–1761 (2021). https://doi.org/10.1007/s12239-021-0150-z

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