Effect of surface roughness and lubrication on the friction coefficient in deep drawing processes of aluminum alloy aa1100 with fem analysis

Abstract

Friction between the interface workpiece and tooling has considerable importance in sheet metal forming
operations; an accurate description of the friction is necessary to analyze and design new workpieces and
tooling. This work suggests a methodology to determine and evaluate the mean coefficient of friction (COF)
using the Finite Element Method (FEM) through Dynaform for the aluminum alloy AA1100. The results
indicate that this methodology is consistent with reality. It is also observed that the software tends to diverge
from the measured results because the software considers the COF to be constant along the process. Despite
this trend, the greatest distance between the maximum drawing force given by the measurement and the
numeric simulation was not high: it was approximately 6%. Workpiece strain measurements were collected
to compare with the numerical simulation results, and it was observed that they are generally in agreement.
Keywords: coefficient of friction, Swift cup test, FE analysis, deep drawing process, Part Design.