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

摘要

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.