Comparison of asperity flattening under different wavelength models for sheet metal forming

Asperity flattening study plays an important role in predicting the friction behavior at the interface and the surface roughness transfer during sheet metal-forming process. This paper presents a comparison of asperity flattening activities under 1-wavelength, 2-wavelength and 3-wavelength finite-element models developed based on a power spectral density (PSD) analysis of measured data on steel sheet surfaces. First, a proper asperity thickness for the modeling has been determined by the investigation of plastic strain distribution along the depth of asperity. The comparison then examines the evolution of real contact area, surface roughness, contact pressure distribution and variation of friction force at the interface between a tool and a workpiece drawn from different wavelength simplification models under various friction conditions. It is concluded that 3-wavelength model has closer results to experimental measurements and introduces less contact area and more local pressure concentrations than those from the other two models.