A friction model for dry contacts during metal-forming processes

In a metal-working process, the friction between the material and the tools influences the process by modifying the strain distribution of the workpiece. This frictional behavior is often taken into account by using a constant coefficient of friction in the finite element simulations. However, friction coefficient varies in time and space with many parameters. This paper aims at modeling of friction in dry contacts which happens at metal-forming processes in the lack of lubricant. The coefficient of dry friction in this model is a function of contact area ratio (which is a function of surface contact characteristics) and strain hardening exponent (material property). The V-bending process of aluminum alloy 6061-T4 sheets was studied experimentally and numerically using ABAQUS/Standard with two kinds of friction models: Coulomb friction and newly developed dry friction models. The results clearly showed that the developed dry friction model has better results in predicting load-stroke curves and springback compared to traditional Coulomb friction model. The FE prediction error for 6061-T4 AA is 16.9% using Coulomb friction model and 9.2% using dry friction model.