Friction and heat partition coefficients in incremental sheet forming process

Qin, Zhenyuan; Gatea, Shakir; Ou, Hengan

Abstract

To understand the thermo-mechanical behaviour in incremental sheet forming (ISF), it is important to precisely determine the interfacial and thermal-relevant parameters including coefficient of friction (COF) and heat partition coefficient (HPC), and to characterise the effect of thermo-mechanically induced heat generation under ISF processing conditions. In the present study, a new tool path-defined straight groove test combined with mechanical and thermal detection is proposed to determine the COF and HPC of Aluminium alloy (AA1050) and commercially pure titanium Grade 1 (CP Ti Grade 1) sheets. The experimental and numerical results show that the determined COF and HPC values are sufficiently accurate. The interaction between friction force and thermal response is observed by this testing method. A novel theoretical thermal model is developed to correlate the relationship between friction-induced heat generation and the thermal effect. The results indicate that the new theoretical model can capture the temperature distribution and variation under different processing conditions, and the results show a good agreement with the finite element (FE) simulation. The presented testing method and theoretical model provide an insight into the determination of the thermal-relevant parameters (COF and HPC), and the quantification of the effect of friction-induced heat generation on the thermal response of the materials.

• Journal Article Type: Article
• Acceptance Date: Jun 7, 2024
• Online Publication Date: Jun 18, 2024
• Publication Date: Aug 30, 2024
• Deposit Date: Jun 18, 2024
• Publicly Available Date: Jun 18, 2024
• Journal: Journal of Manufacturing Processes
• Print ISSN: 1526-6125
• Publisher: Elsevier
• Peer Reviewed: Peer Reviewed
• Volume: 124
• Pages: 503-523
• DOI: https://doi.org/10.1016/j.jmapro.2024.06.015
• Keywords: Incremental sheet forming; Friction coefficient; Heat partition coefficient; Thermal analytical modelling; Temperature prediction
• Public URL: https://nottingham-repository.worktribe.com/output/36290675
• Publisher URL: https://www.sciencedirect.com/science/article/pii/S1526612524005954?via%3Dihub
• Additional Information: This article is maintained by: Elsevier; Article Title: Friction and heat partition coefficients in incremental sheet forming process; Journal Title: Journal of Manufacturing Processes; CrossRef DOI link to publisher maintained version: https://doi.org/10.1016/j.jmapro.2024.06.015; Content Type: article; Copyright: © 2024 The Authors. Published by Elsevier Ltd on behalf of The Society of Manufacturing Engineers.