Abstract
This study investigates the integration of advanced multiscale friction models into commercial finite element codes to enhance the predictive accuracy of forming simulations for Zn-coated steel grades in automotive applications. Numerically generated surface topographies representative of industrial materials were employed to evaluate the influence of key parameters, including surface roughness, lubricant quantity, and blank holder force (BHF), on forming performance. Sensitivity analyses were conducted using finite element simulations, with results highlighting the dominant role of BHF in controlling split risks and the comparatively smaller, yet measurable, effects of material-related parameters. The findings reveal discrepancies between traditional friction models and advanced approaches, particularly in capturing the influence of lubricant variability. By offering insights into the interplay between process control parameters and material related properties, the study provides a framework for optimizing forming processes through surface engineering and advanced modeling techniques, addressing challenges posed by variability in material properties and evolving industrial demands.
Keywords
Friction Stability, Lubricant Variability, Sheet Metal Forming, Surface Topography
Reference
Chezan, T., Baart, P., Hazrati, J., & Pilthammar, J. (2025). Impact of surface engineering on friction stability and forming process variability in automotive components. In Material Forming – ESAFORM 2025, 54 (pp. 1144–1149). Materials Research Forum LLC. Presented at 28th International ESAFORM Conference on Material Forming, ESAFORM 2025, Paestum, May 7-9, 2025. https://doi.org/10.21741/9781644903599-124