Simulation of the Tribological System in Sheet Metal Processes on the Micro Scale

The topography of the sheet metal and tool surface influences the contact behavior between the tool and the sheet metal. With a simulation on the micrometer scale the topographical deformation of the sheet metal is elasto-plastically modeled using an explicit finite element method. The model of the lubricant in between is based on a simplified method calculating the pressure and velocity of the liquid with Darcy’s law. A flat rigid tool is pressed on the sheet metal surface simultaneously with a constant lateral motion. Simulations were performed with real and modeled surfaces. The topographies show different tribological behavior depending on their texture.