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TECHNICAL PAPERS

Mechanics of Surface Roughening in Metal Forming Processes

[+] Author and Article Information
William R. D. Wilson, Weiming Lee

Department of Mechanical Engineering, Northwestern University, Evanston, IL

J. Manuf. Sci. Eng 123(2), 279-283 (Mar 01, 2000) (5 pages) doi:10.1115/1.1363596 History: Received March 01, 1998; Revised March 01, 2000
Copyright © 2001 by ASME
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References

Yamaguchi,  K., and Mellor,  P. B., 1976, “Thickness and Grain Size Dependence of Limit Strains in Sheet Metal Stretching,” Int. J. Mech. Sci., 18, pp. 85–90.
Saha,  P. K., and Wilson,  W. R. D., 1994, “Influence of Plastic Strain on Friction in Sheet Metal Forming,” Wear, 172, pp. 167–173.
Wilson, W. R. D., and Farrell, W. J., 1976, “Lubricant Transport and Breakdown in a High Speed Forging Operation,” Proc. NAMRC IV (SME), pp. 130–137.
Osakada,  K., and Oyane,  M., 1971, “On the Roughening of Free Surface in Deformation processes,” Bull. JSME, 14, pp. 171–177.
Tokizawa,  M., and Yosikawa,  Y., 1973, “The Mechanism of Lubricant Trapping under the Cold Compression of Metals,” J. Jpn. Inst. Met., 37, pp. 19–25.
Chen,  G., Shen,  H., Hu,  S., and Baudelet,  B., 1990, “Roughening of the Free Surfaces of Metallic Sheets during Stretch Forming,” Mat. Sci. Eng., A128, pp. 33–38.
Ratnagar,  D. D., Cheng,  H. S., and Schey,  J. A., 1974, “The Surface Deformation of Aluminum Compressed With Viscous Lubricants,” J. Lubr. Technol., 96, pp. 591–594.
Wilson,  W. R. D., 1977, “Workpiece Surface Roughening in a Hydrodynamically Lubricated Metal Forming Process,” J. Lubr. Technol., 99, pp. 10–14.
Wilson, W. R. D., and Siletto, J. G., 1980, “Surface Roughening in Liquid Lubricated Upsetting,” Metalworking Lubrication, ASME, New York, pp. 87–94.
Wilson, W. R. D., and Schmid, S., 1992, “Surfaces in Metal Rolling,” PED-Vol 62., Engineered Surfaces., Ehmann K. F., and Wilson, W. R. D., eds., ASME, New York, pp. 91–100.
Saha, P. K., Shih, H-C., and Wilson, W. R. D., 1996, “Modeling the Influence of Plastic Strain on Boundary Friction In Sheet Metal Forming,” NAMRI Trans. (SME), pp. 173–180.
Wilson, W. R. D., Malkani, H. G., and Saha, P. K., 1991, “Boundary Friction Measurements Using a New Sheet Metal Forming Simulator,” Proc. NAMRC XIX (SME), pp. 37–42.
Lee, W., 1996, “Surface Roughening in Metal Forming Processes,” Ph.D. Thesis, Mechanical Engineering, Northwestern University, Evanston, IL.
Wilson, W. R. D., and Sheu, S., 1983, “Flattening of Workpice Surface Asperities in Metalforming,” Proc. NAMRC XI (SME), pp. 172–178.
Wilson,  W. R. D., and Sheu,  S., 1988, “Real Area of Contact and Boundary Friction in Metal Forming,” Int. J. Mech. Sci., 30, No. 7, pp. 475–489.

Figures

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SEM of 5052-0 surface rolled to 41 percent reduction
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Profilometer trace of 5052-0 surface stretched by 6.7 percent (Ra=0.29 μm)
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3D AFM plot of 5052-0 surface rolled to 30 percent reduction
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Geometry for upper-bound model
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Results of upper-bound analysis
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Comparison of roughening model with experimental results for 1100-H14
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Comparison of roughening model with experimental results for 5052-0

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