Development of Universal Friction Calibration Curve for Ball Ironing Test
Abstract
:1. Introduction
2. Procedure to Construct the Universal FCC
3. Finite Element Modeling (FEM) Setup
4. Simulation Results
4.1. Effect on the Maximum Load (Lmax)
4.2. Effect on the Final Height (hf)
5. Development of Universal FCC
6. Experiment and Discussion
6.1. Validation of Universal FCC
6.2. Friction Evaluation under Different Testing Conditions
6.3. Friction Evaluation in Thick-Sheet Ironing Process for Pulley Manufacturing
7. Conclusions
- A dimensionless specific load (Ls) was proposed as a new friction indicator for the BIT. It can eliminate the effect of material properties when different materials are used.
- The universal FCC, the Ls-R curve, was developed by using the relationship between the specific loads and thickness reductions under different friction values.
- The BIT with the universal FCC was used to determine the shear friction factor in the actual tribological conditions of the thick-sheet ironing process. The average shear friction factor (m) was determined as 0.06. For validation, this friction value was input into the FEM simulation model to predict the forming results. The forming load and dimension of the product from the simulation were in good agreement with the experimental results. The deviations in load and dimension were less than 2%.
- The ball ironing test with the newly developed FCC is recommended for determining the friction value of the thick-sheet ironing processes.
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Acknowledgments
Conflicts of Interest
Nomenclature
Strain | |
Friction sensitivity parameter | |
Relative velocity | |
Representative stress | |
Normal contact pressure | |
Shear stress | |
Surface expansion ratio | |
L | Load |
Ls | Specific load |
k | Shear strength of material |
m | Shear friction factor |
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Conditions | Details |
---|---|
Materials | AISI-1005, AISI-1015 |
Thickness reduction, R (%) | R44(db41.28), R51(db42.87), R60(db45.00) |
Lubricants | L1, L2, S1 |
Steels | Chemical Composition (wt%) |
---|---|
AISI-1005 | C0.053%, Si0.004%, S0.006%, Mn0.229%, Cr0.013% |
AISI-1015 | C0.161%, Si0.155%, S0.012%, Mn0.514%, Cr0.008% |
Code Names | Details | |
---|---|---|
L1 | Liquid lubricant—additive EP Density at 30 °C (g/mm3) Kinetic viscosity at 40 °C (mm2/s) VI index Flash point temperature (°C) | 0.934 480 98 210 |
L2 | Liquid lubricant—base oil Density at 30 °C (g/mm3) Kinetic viscosity at 40 °C (mm2/s) VI index Flash point temperature (°C) | 0.86 30 n/a 200 |
S1 | Solid lubricant—Zn-Ph coating Combined lubrication layer weight (g/m2) | >8 |
Parameters | Details |
---|---|
Representative stresses, (MPa) | , , |
Stress–strain curve interpolation technique | Linear interpolation, power-law interpolation |
Type of material | AISI-1005, AISI-1015 |
Thickness reduction, R (%) | R40(db40.20)—R65(db46.20) |
Shear friction factors, m | 0–0.4 |
Parameters | Details |
---|---|
Workpiece—material type | Plastic |
Workpiece—flow stress | Obtained from compression test |
Workpiece—number of elements | 8000 elements |
Tooling—material type | Rigid |
Binder force | 16 tons |
Punch speed | 1 mm/s |
Total stroke | 60 mm |
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Sae-eaw, N.; Olarnrithinun, S.; Premanond, V.; Aue-u-lan, Y. Development of Universal Friction Calibration Curve for Ball Ironing Test. Lubricants 2022, 10, 106. https://doi.org/10.3390/lubricants10060106
Sae-eaw N, Olarnrithinun S, Premanond V, Aue-u-lan Y. Development of Universal Friction Calibration Curve for Ball Ironing Test. Lubricants. 2022; 10(6):106. https://doi.org/10.3390/lubricants10060106
Chicago/Turabian StyleSae-eaw, Nuttakorn, Sutee Olarnrithinun, Varunee Premanond, and Yingyot Aue-u-lan. 2022. "Development of Universal Friction Calibration Curve for Ball Ironing Test" Lubricants 10, no. 6: 106. https://doi.org/10.3390/lubricants10060106
APA StyleSae-eaw, N., Olarnrithinun, S., Premanond, V., & Aue-u-lan, Y. (2022). Development of Universal Friction Calibration Curve for Ball Ironing Test. Lubricants, 10(6), 106. https://doi.org/10.3390/lubricants10060106