Experimental verification of a numerical surface roughness model for metallic bodies under large plastic strain

Paweł Sidun

Abstract

The present work describes selected aspects of numerical modelling of the process of bonding metal alloys with consideration for micro-roughness, as well as experimental verification. The plastic-elastic contact between two deformable bodies was investigated in a DEFROM FEM environment, and verified at the test stand. The present paper demonstrates selected results of contact modelling investigated using aluminium-copper samples, in relation to their elastic-plastic range. The real surface profile helped to create a mathematical model of surface roughness measured using a laser microscope. Dependency between a blade of a tool and a feed was used to build a numerical model of roughness based on the arithmetic average value of the roughness profile. The work presents also a process of simplification of real surface roughness for the needs of numerical calculations. The paper investigates an impact of wave roughness at obtained values on effective plastic strain and stress. Additionally, numerical analysis shows a need to enter a new roughness wave correction factor assuming a zero value of the coefficient of friction. This is due to the interaction of metallic surfaces within the plastic contact zone. The obtained results allow the estimation of the impact of surface force interaction expressed by the wave coefficient factor. The experimental verification of numerical calculations allowed the estimation of the actual impact of the micro-cutting process in the entire friction process. Further analysis of obtained results permits the author to explain the surface phenomena occurring during the friction process, such as adhesion or diffusion, and outline the development direction of numerical methods.
Author Paweł Sidun (FME)
Paweł Sidun,,
- Faculty of Mechanical Engineering
Journal seriesMATEC Web of Conferences, ISSN , e-ISSN 2261-236X, (0 pkt)
Issue year2019
Vol252
Pages1-5
Publication size in sheets0.5
ConferenceIII International Conference of Computational Methods in Engineering Science : CMES ’18, Kazimierz Dolny, November 22-24, 2018, 22-11-2018 - 24-11-2018, Kazimierz Dolny, Polska
URL https://www.matec-conferences.org/articles/matecconf/abs/2019/01/matecconf_cmes2018_05005/matecconf_cmes2018_05005.html
Internal identifier000044882
Languageen angielski
LicenseJournal (articles only); published final; Uznanie Autorstwa (CC-BY); with publication
Score (nominal)5
Score sourcejournalList
ScoreBUT score = 0.0, 06-09-2019, manual
Ministerial score = 5.0, 24-02-2020, ArticleFromConference
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