Muhammad Taureza

Improving the Sensitivity of T-Shape Test to Friction Conditions for the Evaluation of Friction Behaviour in Microforming

In this paper, the sensitivity of T-Shape test to friction conditions was evaluated by observing the extrusion height and load curves throughout the normalized stroke (relative to workpiece diameter). Using the finite element code Deform 2D and assuming plane strain approximation, the effects of changing die geometry to the T-Shape test results were investigated. The sensitivity of the T-Shape test was also improved by introducing the double-sloped T-Shape design. The double-sloped T-Shape test was able to separate the extrusion height curves for shear coefficient of friction 0.0 to 0.4 which was unable to distinguish using the original T-Shape setup.

Application of Indentation Size Effect in Finite Element Analysis for Friction Simulation

Contact simulation involving asperities was developed by assuming that the deformation by asperities is equivalent to the deformation by an indenter in a hardness test. Consequently, depth dependent flow stress curves were derived from the indentation size effect model from Abu Al-Rub and were used to simulate the influence of the number of asperities involved during contact on the distribution of contact pressure and the value of effective friction coefficient. Results from simulations suggested that multiplying the number of asperities in contact, when the size of the asperities is comparable to the size of the apparent contact, is not followed by proportional multiplication of the reaction forces. The competing phenomena observed in the simulation are then proposed as an explanation to friction size effect occurring in microforming.

Combined stamping-forging for non-axisymmetric product

Successive combined stamping-forging (CSF) is proposed to produce multi-thickness non-axisymmetric components. This method involves successive compression to create exclusively outward metal flow. Hitherto, the development of CSF has been mostly done for axisymmetric geometry. Using this technique, defect-free rectangular case component with length to thickness ratio of 40 is produced with lower forging pressure. This technology has potential for high throughput production of parts with multiple thicknesses and high width to thickness ratio.