Technical Briefs

Roughening of Free Surface During Sheet Metal Forming

[+] Author and Article Information
Daw-Kwei Leu

e-mail: dkleu@tpcu.edu.tw

Shue-Huye Sheen

e-mail: aimer_07@yahoo.com.tw
Department of Mechanical Engineering,
Taipei Chengshih University of Science and Technology,
No. 2, Xueyuan Road, Beitou, Taipei 112, Taiwan, ROC

1Corresponding author.

Contributed by the Manufacturing Engineering Division of ASME for publication in the Journal of Manufacturing Science and Engineering. Manuscript received January 27, 2012; final manuscript received February 15, 2013; published online March 22, 2013. Assoc. Editor: Jyhwen Wang.

J. Manuf. Sci. Eng 135(2), 024502 (Mar 22, 2013) (4 pages) Paper No: MANU-12-1028; doi: 10.1115/1.4023713 History: Received January 27, 2012; Revised February 15, 2013

This investigation concerns the effect of the process parameters on surface roughening during plastic deformation. The modeling is based on the assumption that surface roughness is proportional to the maximum shear stress on the surface layer. Therefore, an equation is developed in order to describe the relationship between the surface roughness and such process parameters as the initial roughness, grain size, effective strain, and maximum shear strain ratio on the surface layer. In a tensile test, the surface roughness increases nonlinearly with a normal anisotropic value and linearly with the effective strain or grain size. The surface roughness also increases nonlinearly with the effective stress and the strain hardening exponent under some fixed conditions. The normal anisotropic value must be considered in order to evaluate surface roughening during deformation. The experimental results support the proposed model. The proposed model improves our understanding of the mechanism of surface roughening in sheet metal forming.

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Fig. 1

Roughening of the free surface: (a) initial roughness before deformation Ra,1, and (b) surface roughness following deformation Ra,2

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Fig. 2

Stress element under the plane stress condition

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Fig. 3

Shearing of the element results in surface roughening

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Fig. 4

Relationship between the roughness difference ΔR and the normal anisotropic value R

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Fig. 5

Relationship between the roughness difference ΔR and the effective strain ɛe

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Fig. 6

Relationship between the roughness difference ΔR and the grain size D

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Fig. 7

Relationship between the roughness difference ΔR and the effective stress σe

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Fig. 8

Relationship between the roughness difference ΔR and the strain hardening exponent n



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