Friction and Wear Phenomena in Cold Metal Forming: An Integrated Approach

For a given industrial forming process, the bulk behaviour laws in the near-contact surface of the tools and pieces are identified. Finite element models of the process are run to identify the mechanical contact conditions. The mechanical, physical, and chemical contact parameters are then reproduced in an upsetting sliding test. This test involves specimens and contactors taken from industrial workpieces and tools. These tests yield the friction coefficient and the surface quality of the specimens and contactor. A series of accurate correlations are shown between numerical results from finite element method (FEM) real process simulations and industrial data. The final goal of the paper is to apply the methodologies to the monitoring of wear.