Abstract
The galling process remains one of the least understood phenomena in metal forming. The transfer of material from a work-piece onto the tool surface can cause an evolutionary increase in friction coefficient (COF) and thus the use of a constant COF in finite element (FE) simulations leads to progressively inaccurate results. For an aluminium work-piece, material transfer, which has history and pressure dependency, is determined by a dynamic balance between the generation and ejection of wear particles acting as a ‘third body’ abrasive element at the contact interface. To address this dynamic interactive phenomenon, pin-on-disc tests between AA6082 and G3500 were performed under step load change conditions. The COF evolutions, morphologies of the transfer layer and its cross-section were studied. It has been found that contact load change will disequilibrate and rebuild the dynamic balance and high load will increase the generation and ejection rate of third body and vice versa. Moreover, based on the experimental results, an interactive model was developed and presented to simulate the dynamic formation process of the aluminium third body layer under load change conditions, enabling multi-cycle simulations to model the galling distribution and friction variation.
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Acknowledgements
This study was supported by China Scholarship Council (CSC) (Grant No. 201706230235). CSC is a national institution that supports Chinese students to participate in overseas M.S. and Ph.D. programs. This study was also funded by Horizon 2020: research and innovation program as part of the project ‘LoCoMaTech’ (Grant No. 723517). In addition, the strong support from the Institute of Automation, Heilongjiang Academy of Sciences, for this funded research is much appreciated.
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Xiao YANG. She is a Ph.D. candidate in the Department of Mechanical Engineering at Imperial College London, UK. She received her M.S. degree in the Institute of Forming Technology and Equipment, Shanghai Jiao Tong University, China in 2017. Her current research focuses on friction characterisation and interfacial behaviours in hot/warm metal forming processes.
Yiran HU. He received his Ph.D. degree in mechanical engineering from Imperial College London, UK in 2018. He is currently working as a data engineer at Huawei Technologies Co., Ltd. His research interest includes prognostic health management.
Lemeng ZHANG. She is studying for her M.S. degree in mechanical engineering at Imperial College London, UK. She obtained her B.S. degree in 2020 from University College London, UK. Her current research focuses on the development of an autonomous laboratory system to study the friction and lubricant breakdown during hot metal forming.
Yang ZHENG. He received his Ph.D. degree in mechanical engineering from the Imperial College London, UK in 2020. He is currently working as a senior engineer of Huawei Technologies Co., Ltd. His research interests include working towards reliable and safe AI by integrating prior knowledge.
Denis J. POLITIS. He is a lecturer and head of the Manufacturing and Materials Modelling laboratory in the Department of Mechanical and Manufacturing Engineering at the University of Cyprus. He has more than 10-year research experience in sheet metal forming and forging technologies. He has worked on numerous research projects in collaboration with industrial companies that have been sponsored by European FP7 and H2020 grants.
Xiaochuan LIU. He is an assistant professor in the Department of Mechanical Engineering, Xi’an Jiaotong University, China, who obtained his B.Eng. degree from University of Sheffield, M.Sc. and Ph.D. degrees from Imperial College London. His research is focused on the material properties and modelling, cloud FEA and advanced forming technology for lightweight materials, including aluminium alloys, titanium alloys and composites.
Li-Liang WANG. He is the head of Metal Forming and Modelling Group at Imperial College London. His major research interests include the design and development of advanced metal forming technologies and manufacturing system. His work has made fundamental contributions to the characterization and modelling of materials and interfacial behaviours of engineering materials.
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Yang, X., Hu, Y., Zhang, L. et al. Experimental and modelling study of interaction between friction and galling under contact load change conditions. Friction 10, 454–472 (2022). https://doi.org/10.1007/s40544-021-0531-3
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DOI: https://doi.org/10.1007/s40544-021-0531-3