Masen, M.A.

Rooij, M.B. de

English

Masen, Marc Arthur

de Rooij, Matthias B.

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Abrasive Wear between Rough Surfaces in Deep Drawing

University of Twente Research Information

Fifth Engineering Mechanics Symposium, Nov. 2002 18Abrasive Wear between Rough Surfacesin Deep DrawingM.A. Masen & M.B. de RooijUniversity of Twente, Twente Institute of MechanicsSurface Technology and Tribology GroupP.O.Box 217, 7500 AE Enschede, The NetherlandsPhone: +31 53 489 4390, e-mail: m.a.masen@ctw.utwente.nlA recent development in sheet metal forming industry is the application of tailored blanks: blanksprepared from separate pieces of sheet material, welded together prior to the forming process. Thepieces of sheet material can have different properties, enabling weight reduction of components,corrosion resistance using cathodic protection or the possibility to create local weak spots, resulting inwell defined deformation zones in the event of an accident (e.g. crash zones in automotiveapplications). However, a major draw back in the utilisation of these pre-welded or tailored blanks isthat the weld between the pieces of sheet exhibits increased hardness and roughness, leading topossible abrasive wear of the sheet metal forming tool [1]. In this work a model is developeddescribing the abrasive wear of deep drawing dies caused by the application of tailored blanks.Many surface contact models are based on the assumption that surfaces are composed of acollection of small asperities of which the tips are equally sized and spherically shaped and havesome kind of statistical height distribution. This approach w as used in 1966 by Greenwood andWilliamson [2] and was successfully followed by many researchers during the following decades. Thestatistical representation of surface topography enables calculation of contact forces and asperitydeformations with reasonable accuracy using well-established equations. Although this approach hasproven to be suitable for static contact situations, alternative representations of the surfacetopography are required w hen modelling abrasive wear. In the current work an elastoplastic contactmodel is developed in which a representation of the surface topography is obtained by best-fitapproximations of the microcontacts, obtained from real, measured surface height data. In thisdeterministic surface representation the tips of the contacting asperities are assumed to have anellipsoidal shape. Given the material parameters and contact conditions, the load and deformation ofa single asperity can be computed. Subsequently, the wear induced by each individual asperity isobtained by inserting its size and shape and the conditions into a single asperity micro-abrasionmodel. By summing the contributions of all individual asperities, the total abrasive w ear volume isobtained. The results of the developed abrasive wear model are compared with results obtainedusing a statistical approach.References:[1] Vermeulen, M., (1997), Effect of Pre-Welded Blanks on the W ear of Deep Drawing Tools, Abstracts ofpapers, 1st World Tribology Congress, London, pp. 333, ISBN 1 86058 109 9.[2] Greenwood, J.A., and Williamson, J.B.P., (1966), Contact of nominally flat surfaces, Proc. R. Soc. Lond. A,Vol. 295, pp. 300  319.

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Abrasive Wear between Rough Surfaces in Deep Drawing

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University of Twente Research Information