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Topics
• Tribology
• Measurement of friction
Introduction
Machine parts: the points of the contact surface moving with equal
velocity.
Workpiece during forming: the velocity of the contact surface can be
different in different positions.
The metals surface always covered with an oxide layer (hot forming)
which chemical and physical properties differ from those of the base
metal, and significantly affect the friction.
The hardness of the forming tool is always notably higher that that of
workpiece, while the tool’s surface roughness is lower. The workpiece is
going to have the shape of the tools’ geometry
The relative velocity of moving surface is usually lower during forming
techniques, than in machines.
Friction coefficient
Amonton-Coulomb friction:
If a body are pressed with a force Q to an other one, then
𝑆 = 𝜇𝑄 force is necessary to move it.
𝑆=𝜇𝑄
𝑆 𝑄
=𝜇
𝐴 𝐴
tool
𝜏=𝜇𝑞
Shear friction:
𝑣𝑟𝑒𝑙 𝜎𝑦𝑖𝑒𝑙𝑑
𝑣𝑟𝑒𝑙 𝜏=𝑚 0≤𝑚≤1
3
workpiece
Contact, friction
Lubricant’s behavior
1
𝜉= 𝜏
𝜂
Fluid friction
𝑑𝑣
𝜏=𝜂
𝑑ℎ
𝜇 – friction coefficient (dry friction)
ℎ - gap
𝑣 – relative velocity
𝑞 – pressure
𝜂 - viscosity 𝑑𝑣
𝜏 = 𝜇𝑞(1 + 𝛾) + 𝜂 𝛾
𝑑ℎ
𝛾 = 0. . 1 - lubrication coefficient
Stribeck diagram
Dry friction
Boundary friction
Mixed friction
Thick film state: The thickness of the lubricant film is one order of
magnitude larger than the contact surfaces’ roughness. Hydrodynamic
friction. From the aspect of forming, the loadability of the surfaces are
not significant.
Thin film state: The film thickness decreases due to increased pressure,
decrease of viscosity (effect of temperature). The thickness of the
lubricant film is 3-5 times larger than the contact surfaces’ roughness.
The tool and the workpiece is in contact in certain points, which cases
higher friction coefficient than in the previous case. Wear effect
Mixed friction state. The workpiece-tool contact area is significant. The
thickness of the lubricant film is maximum 3 times larger than the
contact surfaces’ roughness. By appropriate choice of lubricant few
molecule thick layer is formed on the surfaces, which prevent the
metal-metal contact and so reduces the wear
Boundary friction state. The load is transmitted through the contacting
surfaces, but the boundary layer on the surfaces prevent the direct
contact.
The friction’s effect on forming processes
The friction lead to unequal distribution of strain, and thus influences the
stress state. Different strain leads to different hardening: the mechanical
properties will be inhomogeneous
Due to the friction forces higher forming forces are needed, and the
load on tools are also higher.
The wear caused by friction decreases the service life of the tool, and
reduces the surface quality of the workpieces.
incompressibility
𝜕𝑣𝑟 𝑣𝑟 𝜕𝑣𝑧
𝑑𝑖𝑣 𝑣 = + + =0
𝜕𝑟 𝑟 𝜕𝑧
1𝜕 𝜕𝑣𝑧
(𝑣 𝑟) + =0
𝑟 𝜕𝑟 𝑟 𝜕𝑧
𝜕𝑣𝑧 𝜕𝑣𝑟
𝑣𝑟 𝑟 = −𝑟 𝑑𝑟 𝜉𝑟𝑟 =
𝜕𝑧 𝜕𝑟
𝑣0 𝑟 𝑣𝑟
𝑣𝑟 = +𝐶 𝜉𝜑𝜑 =
2ℎ 𝑟
𝜕𝑣𝑧
𝜉𝑧𝑧 =
𝜕𝑧
Friction coefficient measurement
𝑣𝑟
𝑣0 𝑟 𝑣 = 𝑣𝜑
𝑣𝑟 = +𝐶
2ℎ 𝑣𝑧
𝑣0 𝑟
𝑣𝑟 𝑎𝑡 𝑟=𝜌 = 0 = +𝐶
2ℎ
𝑣0 2
𝐶=− 𝜌
2ℎ
𝑣0 𝜌2
𝑣𝑟 = 𝑟−
2ℎ 𝑟
𝑣0 𝜌2
𝜉𝑟𝑟 = 1+ 2
2ℎ 𝑟
𝑣0 𝜌4 𝜌2
𝑣0 𝜌2 𝜉= 3+ 4 1+ 2
𝜉𝜑𝜑 = 1− 2 3ℎ 𝑟 𝑟
2ℎ 𝑟
𝑣0
𝜉𝑧𝑧 = −
ℎ
Friction coefficient measurement
equilibrium
𝝃 = 𝜆𝝈′
Friction coefficient measurement
Yield criteria
1 2 2 2
𝜎𝑦𝑖𝑒𝑙𝑑 = 𝜎𝑀𝑖𝑠𝑒𝑠 = (𝜎𝑟𝑟 − 𝜎𝜑𝜑)2+(𝜎𝑧𝑧 − 𝜎𝜑𝜑 )2+(𝜎𝑟𝑟 − 𝜎𝜑𝜑 )2+6(𝜎𝑟𝜑 + 𝜎𝑟𝑧 + 𝜎𝑧𝜑 )
2
𝜎𝑦
𝜎𝑦 In the external zone (k)
𝜎𝑦
𝜎𝑦
𝜎𝑦
In the internal zone (b)
𝜎𝑦 𝜎𝑦
Friction coefficient measurement
𝜌
Friction coefficient measurement
𝑆ℎ𝑒𝑎𝑟 𝑓𝑟𝑖𝑐𝑡𝑖𝑜𝑛