This paper presents a new modelling approach for liquid lubricant behavior in metal forming operations by focusing on the hydrodynamic pressure build-up in micro pockets. Theoretical and numerical fundamentals of the proposed approach are introduced, and upsetting of an aluminum cylinder with an artificial lubricant pocket is presented as a validation case. The proposed numerical framework splits the fluid-solid interaction model into a computational fluid dynamics and solid mechanics part. While the solid mechanics part employs the Lagrangian finite element flow formulation for plastic deformation, the fluid dynamics part is built upon the set of Navier-Stokes equations applying an Eulerian finite element method in combination with an Arbitrary Langagian Eulerian formalism. The latter enables the displacement based coupling from the solid to the fluid. The fluid-to-solid coupling is pressure based and enabled by the finite element flow formulation’s inherent velocity-pressure characteristics. The weak coupling avoids ill-conditioning of the system matrix and makes it possible to benefit from both Lagrangian and Eulerian meshes.
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