Mechanism-Based Modelling of Wear in Sheet-Bulk Metal Forming

Friction characteristics and wear of sheet-bulk metal forming tools featuring microstructured surfaces are simulated on the mesoscale. Computational homogenisation is used for surface cut-outs on which the structures are geometrically resolved and where friction laws model lower scale roughness. Two approaches are presented for the modelling of wear. A dissipation based Archard model is implemented in a Python postprocessor geometry-update scheme using Abaqus/Standard as Finite Element solver. Sinusoidal surface structures exhibit anisotropic adaption of friction coefficients which is preserved throughout severe surface wear. Bionic isotropic structures feature quasi-isotropic friction adaption, where the sliding direction along the edges of the structure experiences a faster wear evolution. Experimental comparisons show good qualitative agreement, although more investigations are required. Results can provide load-dependent coefficients for macro-simulations as well as insights on precise characteristics. A mechanism-based approach uses the Particle-Finite-Element Method towards the simulation of particle abrasion. The shape detection method is detailed along with a focus on the Contact Domain Method with examples showing the ability to model material separation. Inelastic material behaviour and more robust contact approximations have to be included to allow for wear simulations. First studies on lubrication propose the use of the viscoelastic Norton-model for simulating drawing grease.