Contact simulation for predicting surface topography in metal forming

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Abstract

A surface contact model that takes account of flattening, roughening and tool elastic microwedge effects on workpiece surface is developed. The model can be implemented in FEM codes to predict the final surface qualities of the products in metal forming. As an example, the proposed model has been combined with a membrane finite element code of sheet metal forming process to predict the contact area ratio, surface roughness and mean asperity spacing. Numerical results showed good agreement with the experiments.

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