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Lubricated Contact Model for Metal Forming Processes in OpenFOAM

Numerical method for calculating lubricated contact pressures and frictional forces is presented in this study. Lubrication and friction are important factors in metal forming processes, since unoptimised manufacturing parameters can result in lower productivity of the process and deteriorate surface quality of the product. In order to have a good representation of the lubricated contact phenomena, interaction between surface asperities and lubricant should be taken into account [1]. Due to changes of lubricant thickness during lubricated metal forming process, continuous treatment of lubrication regimes (hydrodynamic, mixed and boundary) is required. Surface roughness effects, lubrication regimes treatment and lubricant properties variations are all implemented in the model [2]. Contact pressures and frictional forces are calculated by the modified Reynolds equation [3] using the Finite Area discretisation [4]. The Reynolds equation is implemented in its compressible form which enables the analysis of cavitation effects which might occur during lubricated contact. The flow factors required by the modified Reynolds equation are calculated using the flow factor equations for lubricated contact with large fractional asperity contact areas by Wilson and Marsault [5]. The implemented asperity contact model [6] takes into account elasto-plastic deformation of asperities. Implemented model is used by the solid contact boundary condition for a large strain elasto- plastic deformation solver developed by Cardiff et al. [7] in OpenFOAM framework. Results of the numerical simulation using the implemented model are shown on a wire drawing case.

Lubricated Contact ; Finite Area Method ; Reynolds Lubrication Equation ; OpenFOAM

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