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Evaluation of the friction coefficient in tube hydroforming with the “corner filling test” in a square section die

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Abstract

Friction conditions are very critical in metal forming because they can lead to important thinning in the final manufactured product. The value of the friction coefficient is then of particular importance for performing predictive finite element (FE) simulation of forming operations. Classically, numerical simulations are run with values of the friction coefficient found in technical database where the Coulomb’s coefficient has been evaluated with the pin-on-disk test. Moreover, the friction coefficient is often used as a set up parameter for running FE simulations. The pin-on-disk test is not automatically suitable for characterizing the friction coefficient in tube hydroforming. The “corner filling” test has been developed for tube hydroforming and several authors have developed analytical models for representing this test. Among them, the authors have chosen to exploit the Orban-Hu model. This model permits to build graphs. On those graphs, experimental data are overlaid in order to evaluate the friction coefficient. Thus, a friction coefficient (μ) of 0.4 has been found by the proposed method against the value of about 0.1 found in technical database. FE simulations with 3D shell and 3D solid models have been performed with the two values of the friction coefficients. The conclusion is that FE simulations with 3D shell model permit definitely better predictions for thickness evaluation. Moreover, running the simulations with μ = 0.4 leads to a more critical representation of the minimal thickness in the final component. Finally, an experimental method is proposed for the evaluation of the friction coefficient without advanced numerical methods.

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Authors and Affiliations

  1. Laboratoire Génie des Matériaux et Environnement (LGME), Ecole Nationale d’Ingénieurs de Sfax (ENIS), B.P.1173-3038, Sfax, Tunisie

    Abir Abdelkefi, Noamen Guermazi & Nader Haddar

  2. Département de Mécanique Appliquée, Institut FEMTO-ST, 24 rue de l’Epitaphe, 25000, Besançon, France

    Abir Abdelkefi, Pierrick Malécot & Nathalie Boudeau

  3. ENSMM, 26 rue de l’Epitaphe, 25030, Besançon, Cedex, France

    Pierrick Malécot & Nathalie Boudeau

  4. COMUE UBFC, Besançon, France

    Pierrick Malécot & Nathalie Boudeau

Authors
  1. Abir Abdelkefi
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  2. Pierrick Malécot
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  3. Nathalie Boudeau
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  4. Noamen Guermazi
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  5. Nader Haddar
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Corresponding author

Correspondence to Noamen Guermazi.

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Abdelkefi, A., Malécot, P., Boudeau, N. et al. Evaluation of the friction coefficient in tube hydroforming with the “corner filling test” in a square section die. Int J Adv Manuf Technol 88, 2265–2273 (2017). https://doi.org/10.1007/s00170-016-8945-1

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  • DOI: https://doi.org/10.1007/s00170-016-8945-1

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