Due to extreme interface pressures in plastic deformation processing of metals, it is very unlikely for a thick film of lubricant to sustain, particularly so at low and medium speeds of sliding. Consequently mixed and boundary lubrication regimes exist resulting in partial metal-to-metal contact. The nature of contact and deformation at the asperity level affect the severity of stress conditions on the workpiece surface and in turn the quality of the product. This paper analyzes the asperity interaction between a rigid tool and a soft workpiece while the latter is subjected to plastic deformation under boundary-lubricated conditions. Galerkin finite element method has been used to model the deformation of single asperity contact. The soft asperity is modeled as a plastically deforming von-Mises material under the frictional contact with the hard and rigid asperity. The conclusions are drawn on the tribological behavior at the contact and quality of the product from the results of this analysis.
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