Friction

Topics

• Tribology

• Different friction models

• Role of lubricants and requirements

• Measurement of friction
 Introduction

Tribology is the study of interaction of surfaces due to their

relative motion.
Wear processes occur on touching and sliding surfaces under
load. These have a significant influence on the forming
processes.

The friction is an effect hindering the displacement of the

surfaces, and can be characterized with the force trying to
hinder the motion. During friction particles are separating from
the bodies and „welded” to other particles or surfaces.

This is the phenomenon of wearing, where (1) material loss,

dimension change occur and (2) the surfaces are damaged.

Damage of workpiece’s surface: production quality problem.

Damage of tools’s surface: reduced service life
 Introduction

Base on the lubrication state the following friction types are

differentiated:
Dry friction: there is no third media between the surfaces, but
metallic contact. In this state the friction properties are
determined by the properties of the material and the
characteristics of the geometry (surface roughness).
Boundary friction: There is a thin layer of oxide or lubricant on
the surfaces. The friction process is mainly determined by the
properties of this layer.
Mixed friction: On some areas dry or boundary friction is
characteristic, while on other areas the surfaces are separated
by fluid.
Fluid friction (hydrodynamic): The moving surfaces are fully
separated by a fluid (or gas). The friction force is determined by
the viscosity of the fluid: The inner friction of the fluid is
significant- Newtonian fluid
 Introduction

The pressure between the surfaces is high in forming technologies,

higher than in bearings, can reach 2500 MPa or even higher.
The contact surface can undergo extensive deformation due to the
high pressure. The geometry changes and the contact area increases.

Machine parts: the points of the contact surface moving with equal
velocity.
Workpiece during forming: the velocity of the contact surface can be
different in different positions.

The metals surface always covered with an oxide layer (hot forming)
which chemical and physical properties differ from those of the base
metal, and significantly affect the friction.
The hardness of the forming tool is always notably higher that that of
workpiece, while the tool’s surface roughness is lower. The workpiece is
going to have the shape of the tools’ geometry
The relative velocity of moving surface is usually lower during forming
techniques, than in machines.
 Friction coefficient

Amonton-Coulomb friction:
If a body are pressed with a force Q to an other one, then
𝑆 = 𝜇𝑄 force is necessary to move it.
𝑆=𝜇𝑄

𝑆 𝑄
=𝜇
𝐴 𝐴

tool
𝜏=𝜇𝑞

Shear friction:

𝑣𝑟𝑒𝑙 𝜎𝑦𝑖𝑒𝑙𝑑
𝑣𝑟𝑒𝑙 𝜏=𝑚 0≤𝑚≤1
3
workpiece
 Contact, friction

Lubricant’s behavior
1
𝜉= 𝜏
𝜂
Fluid friction

𝑑𝑣
𝜏=𝜂
𝑑ℎ
𝜇 – friction coefficient (dry friction)
ℎ - gap
𝑣 – relative velocity
𝑞 – pressure
𝜂 - viscosity 𝑑𝑣
𝜏 = 𝜇𝑞(1 + 𝛾) + 𝜂 𝛾
𝑑ℎ
𝛾 = 0. . 1 - lubrication coefficient
 Stribeck diagram

Dry friction
Boundary friction

Mixed friction

Fluid (hydrodynamic) friction

 Stribeck diagram

Thick film state: The thickness of the lubricant film is one order of
magnitude larger than the contact surfaces’ roughness. Hydrodynamic
friction. From the aspect of forming, the loadability of the surfaces are
not significant.
Thin film state: The film thickness decreases due to increased pressure,
decrease of viscosity (effect of temperature). The thickness of the
lubricant film is 3-5 times larger than the contact surfaces’ roughness.
The tool and the workpiece is in contact in certain points, which cases
higher friction coefficient than in the previous case. Wear effect
Mixed friction state. The workpiece-tool contact area is significant. The
thickness of the lubricant film is maximum 3 times larger than the
contact surfaces’ roughness. By appropriate choice of lubricant few
molecule thick layer is formed on the surfaces, which prevent the
metal-metal contact and so reduces the wear
Boundary friction state. The load is transmitted through the contacting
surfaces, but the boundary layer on the surfaces prevent the direct
contact.
 The friction’s effect on forming processes

The friction lead to unequal distribution of strain, and thus influences the
stress state. Different strain leads to different hardening: the mechanical
properties will be inhomogeneous

Due to the friction forces higher forming forces are needed, and the
load on tools are also higher.

The wear caused by friction decreases the service life of the tool, and
reduces the surface quality of the workpieces.

The harmful consequences of the friction can be reduced by

lubrication. This can make the technology more complicated.
The treatment and lubrication of the surfaces prior to the forming as
well as the removal of the lubrication after the process is costly
 Lubricants - requirements
• Physical, chemical and rheological properties must fit to the friction
characteristics of the forming process and to the materials of the
tools and workpiece
• Their physical, chemical and rheological properties must be stable.
(heat, pressure)
• good cohesion and easy removal from the workpiece and tool
• direction independent properties
• Must not be toxic and harmful to the environment
• Must not cause corrosion
• Stability of properties, and good storability
• Must be able to apply to the workpiece’s or tool’s surface with the
recent technologies and tools
• Not too expensive
 Lubricants - roles

• Separation of the tool’s and workpiece’s surfaces

• Decreasing of the friction forces where they have disadvantageous
effect on the deformation of the workpiece and on stability of the
process.
• Decreasing of the tool wear effect, increase the service life
• Preserve or improve the surface quality of the workpiece
• Temporarily corrosion protection of the workpiece
• Cooling effect during the forming process
 Friction coefficient measurement
𝑣𝑟
Ring upsetting 𝑣 = 𝑣𝜑
𝑣𝑧
Kinematic analysis
𝑧 = 0 𝑣𝑧 = 0 𝑣0
𝑣𝑧 = −
𝑧 = ℎ 𝑣𝑧 = −𝑣0 ℎ

incompressibility

𝜕𝑣𝑟 𝑣𝑟 𝜕𝑣𝑧
𝑑𝑖𝑣 𝑣 = + + =0
𝜕𝑟 𝑟 𝜕𝑧
1𝜕 𝜕𝑣𝑧
(𝑣 𝑟) + =0
𝑟 𝜕𝑟 𝑟 𝜕𝑧
𝜕𝑣𝑧 𝜕𝑣𝑟
𝑣𝑟 𝑟 = −𝑟 𝑑𝑟 𝜉𝑟𝑟 =
𝜕𝑧 𝜕𝑟
𝑣0 𝑟 𝑣𝑟
𝑣𝑟 = +𝐶 𝜉𝜑𝜑 =
2ℎ 𝑟
𝜕𝑣𝑧
𝜉𝑧𝑧 =
𝜕𝑧
 Friction coefficient measurement
𝑣𝑟
𝑣0 𝑟 𝑣 = 𝑣𝜑
𝑣𝑟 = +𝐶
2ℎ 𝑣𝑧
𝑣0 𝑟
𝑣𝑟 𝑎𝑡 𝑟=𝜌 = 0 = +𝐶
2ℎ
𝑣0 2
𝐶=− 𝜌
2ℎ
𝑣0 𝜌2
𝑣𝑟 = 𝑟−
2ℎ 𝑟

𝑣0 𝜌2
𝜉𝑟𝑟 = 1+ 2
2ℎ 𝑟
𝑣0 𝜌4 𝜌2
𝑣0 𝜌2 𝜉= 3+ 4 1+ 2
𝜉𝜑𝜑 = 1− 2 3ℎ 𝑟 𝑟
2ℎ 𝑟
𝑣0
𝜉𝑧𝑧 = −
ℎ
 Friction coefficient measurement

equilibrium

According to the Levy-Mises equation

𝝃 = 𝜆𝝈′
 Friction coefficient measurement

Yield criteria
1 2 2 2
𝜎𝑦𝑖𝑒𝑙𝑑 = 𝜎𝑀𝑖𝑠𝑒𝑠 = (𝜎𝑟𝑟 − 𝜎𝜑𝜑)2+(𝜎𝑧𝑧 − 𝜎𝜑𝜑 )2+(𝜎𝑟𝑟 − 𝜎𝜑𝜑 )2+6(𝜎𝑟𝜑 + 𝜎𝑟𝑧 + 𝜎𝑧𝜑 )
2

The z=0 plane is at the half height of the ring:

Equilibrium equation containing the yield criteria:

Appying Shear friction model:

 Friction coefficient measurement

Calculate the radial stress in the z=0 plane

𝜎𝑦
𝜎𝑦 In the external zone (k)

𝜎𝑦

𝜎𝑦
𝜎𝑦
In the internal zone (b)
𝜎𝑦 𝜎𝑦
 Friction coefficient measurement

On the surface 𝜌 separating the two regions, the radial

stresses are equal with opposit sign.

𝜌
Friction coefficient measurement

𝑆ℎ𝑒𝑎𝑟 𝑓𝑟𝑖𝑐𝑡𝑖𝑜𝑛