Influence of geometric configurations on friction characteristics during incremental forming process of AA5052 sheet metal  

几何构型对AA5052板材渐进成形过程摩擦特性的影响

作　　者：Guang-can YANG Da-wei ZHANG Chong TIAN Sheng-dun ZHAO 杨光灿;张大伟;田冲;赵升吨(西安交通大学机械工程学院,西安710049)

机构地区：[1]School of Mechanical Engineering,Xi’an Jiaotong University,Xi’an 710049,China

出　　处：《Transactions of Nonferrous Metals Society of China》2025年第3期715-733,共19页中国有色金属学报(英文版)

基　　金：the support of the Key Research and Development Program of Shaanxi Province,China(No.2021GXLH-Z-049)。

摘　　要：The influence of geometric configuration on the friction characteristics during incremental sheet forming of AA5052 was analyzed by integrating surface morphology and its characteristic parameters,along with plastic strain,contact pressure,and area.The interface promotes lubrication and support when wall angles were≤40°,a 0.5 mm-thin sheet was used,and a 10 mm-large tool radius was employed.This mainly results in micro-plowing and plastic extrusion flow,leading to lower friction coefficient.However,when wall angles exceed 40°,significant plastic strain roughening occurs,leading to inadequate lubrication on the newly formed surface.Increased sheet thickness and decreased tool radius elevate contact pressure.These actions trigger micro-cutting and adhesion,potentially leading to localized scuffing and dimple tears,and higher friction coefficient.The friction mechanisms remain unaffected by the part’s plane curve features.As the forming process progresses,abrasive wear intensifies,and surface morphology evolves unfavorably for lubrication and friction reduction.将表面形貌及其特征参数与塑性应变、接触压强及面积结合,分析几何构型对AA5052板材渐进成形过程摩擦特性的影响。结果表明:当壁角≤40°、厚度0.5 mm的薄板、10 mm的大工具半径成形时,表面形貌有利于润滑和支撑,界面发生微犁沟和塑性挤压作用,表现出较小的摩擦因数。当壁角大于40°时,应变粗糙化显著,导致新生表面未及时被润滑,而增加板厚和减小工具半径会增大接触压强。上述作用会触发微切削和黏着作用,甚至发生局部咬死形成韧窝撕裂,表现出更高的摩擦因数。零件的平面曲线特征不会影响界面的摩擦作用机制。此外,随着成形过程的进行,磨粒磨损加剧,表面形貌向着不利于润滑减摩方向演变。

关 键 词：AA5052 sheet metal incremental forming process geometric configurations surface morphology characteristics friction mechanism 

分 类 号：TG1[金属学及工艺—金属学]