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A finite strain contact model for mixed lubricated surfaces in forming processes

机译：成形过程中混合润滑表面的有限应变接触模型

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For an accurate simulation of forming processes, it is of paramount importance to model the different lubrication regimes that can develop at the contact interface. These might vary from zone to zone of the forming piece, and from one regime to another, resulting in forces of different nature and magnitude. In these cases, the use of the classical Coulomb friction law will be clearly not sufficient to capture, in a suitable manner, the variety of forces applied on the forming piece. Objective of this paper is the development of a constitutive model for the contact interface that is able to capture the different lubrication regimes. The load bearing capacity of the contact interface is assumed to be the resultant of two mechanisms: dry friction arising from the solid contact asperities, and hydrodynamic fluid film lubrication. The activation of one, the other or both mechanisms is controlled by a parameter α that, in the proposed model, depends on the current value of the sliding velocity V, the interfacial separation D and the surface roughness σ_s. The functional relation definingαcan be derived either from experimental fitting of some parameters, which can be introduced into a predefined analytical expression designed to reflect the variation of the different regimes, or from the application of a sequential multiscale analysis through the use of microscale models. The model is formulated with respect to a converted reference frame, so to make it amenable for large deformation simulations. The numerical integration scheme of the resulting initial constitutive value problem is presented and implemented into an explicit finite element code. The mechanisms of the interface model have been separately tested and the numerical results correlate well with the available experimental findings. Comparisons with the Coulomb friction model are also provided. The applicability of the model for forming simulations is then demonstrated by reproducing the manufacturing of a ridge on an aluminum tube for the cosmetic industry, using the hydroforming technique. Both an elastomer and the fluid have been employed as pressure medium, and their performance has been compared in terms of the stresses and deformations produced in the finished product.
机译：对于成型过程的精确模拟，建模可能在接触界面处形成的不同润滑方式至关重要。这些可能在成型件的区域之间以及从一个区域到另一个区域都不同，从而导致不同性质和大小的力。在这些情况下，使用经典的库仑摩擦定律显然不足以以适当的方式捕获施加在成型件上的各种力。本文的目的是开发一种能够捕获不同润滑方式的接触界面的本构模型。假定接触界面的承载能力是两种机理的结果：由固体接触粗糙引起的干摩擦和流体动力液膜润滑。一个，另一个或两个机制的激活由参数α控制，在建议的模型中，该参数取决于滑动速度V，界面间距D和表面粗糙度σ_s的当前值。可以从一些参数的实验拟合中得出定义功能关系的方法，可以将其引入旨在反映不同状态变化的预定义分析表达式中，也可以通过使用微观模型对顺序多尺度分析进行应用。该模型是针对转换后的参考系制定的，因此适合大型变形仿真。给出了所得初始本构值问题的数值积分方案，并将其实现为显式的有限元代码。界面模型的机制已经过单独测试，数值结果与可用的实验结果紧密相关。还提供了与库仑摩擦模型的比较。然后，通过使用液压成型技术，通过在化妆品行业的铝管上复制凸脊的制造过程，来证明该模型在成型模拟中的适用性。弹性体和流体均已被用作压力介质，并且根据成品中产生的应力和变形对它们的性能进行了比较。

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