Finite element simulation of tip test with an aluminum alloy

Abstract

Finite element simulations are being widely used to increase the efficiency and effectiveness of design of bulk metal forming processes. In such simulations, proper consideration of friction condition is important in obtaining reliable results and the shear friction factor is widely used for bulk deformation for this purpose. In the earlier work for estimation of the shear friction factor, a radial tip was formed on the backward extruded end of the workpiece named 'tip test'. It has been found that simple measurement of this radial tip distance from the external side surface of the deformed AL6061-0 workpiece can be used to effectively determine the shear friction factor due to the linear relationship between the two. In the present investigation, the friction conditions at the punch and bottom die interfaces were determined based on finite element simulations. The shear friction factor at the bottom die was found to be about 60% of the one at the punch. The predicted shear friction factors compared well to the values obtained from the ring compression test. (C) 2004 Elsevier B.V. All rights reserved.