A new empirical relation for the conventional measures of free surface roughness is proposed. Its geometric interpretation is a surface in three-dimensional space. A set of tests feasible for practical realization is discussed. Some available experimental and numerical results are used to reveal various qualitative features of the geometric surface. In particular, a reasonable assumption is that it is a ruled surface for a class of materials. A typical cross section of the surface, which is a curve, has an axis of symmetry if the roughening rate is independent of the sense of the strain rate normal to the material surface, where the roughness parameters should be predicted. The curve has a minimum at the axis of symmetry. Finally, there are two points, where the curve has a maximum. A simple analytic expression to specify the relation proposed for a given material is provided to fit experimental data.

1.
Fukuda
,
M.
,
Yamaguchi
,
K.
,
Takakura
,
N.
, and
Sakano
,
Y.
, 1974, “
Roughening Phenomenon on Free Surface of Products in Sheet Metal Forming
,”
J. Jpn. Soc. Technol. Plast.
0038-1586,
15
(
167
), pp.
994
1002
.
2.
Parmar
,
A.
,
Mellor
,
P. B.
, and
Chakrabarty
,
J.
, 1977, “
A New Model for the Prediction of Instability and Limit Strains in Thin Sheet Metal
,”
Int. J. Mech. Sci.
0020-7403,
19
, pp.
389
398
.
3.
Jain
,
M.
,
Lloyd
,
D. J.
, and
Macewen
,
S. R.
, 1996, “
Hardening Laws, Surface Roughness and Biaxial Tensile Limit Strains of Sheet Aluminium Alloys
,”
Int. J. Mech. Sci.
0020-7403,
38
, pp.
219
232
.
4.
Yamaguchi
,
K.
, and
Mellor
,
P. B.
, 1976, “
Thickness and Grain Size Dependence of Limit Strains in Sheet Metal Stretching
,”
Int. J. Mech. Sci.
0020-7403,
18
, pp.
85
90
.
5.
Sundaram
,
P. A.
, 1995, “
Deformation-Induced Surface Roughening Studies in an AISI 1090 Spheroidized Steel
,”
Scr. Metall. Mater.
0956-716X,
33
, pp.
1093
1099
.
6.
Mahmudi
,
R.
, and
Mehdizadeh
,
M.
, 1998, “
Surface Roughening During Uniaxial and Equi-Biaxial Stretching of 70-30 Brass Sheets
,”
J. Mater. Process. Technol.
0924-0136,
80–81
, pp.
707
712
.
7.
Thomson
,
P. F.
, and
Nayak
,
P. U.
, 1980, “
The Effect of Plastic Deformation on the Roughening of Free Surfaces of Sheet Metal
,”
Int. J. Mach. Tool Des. Res.
0020-7357,
20
, pp.
73
86
.
8.
Wichern
,
C. M.
,
De Cooman
,
B. C.
, and
Van Tyne
,
C. J.
, 2005, “
Surface Roughness of a Hot-Dipped Galvanized Sheet Steel as a Function of Deformation Mode
,”
J. Mater. Process. Technol.
0924-0136,
160
, pp.
278
288
.
9.
Stoudt
,
M. R.
,
Hubbard
,
J. B.
,
Iadicola
,
M. A.
, and
Banovic
,
S. W.
, 2009, “
A Study of the Fundamental Relationships Between Deformation-Induced Surface Roughness and Strain Localization in AA5754
,”
Metall. Mater. Trans. A
1073-5623,
40
(
7
), pp.
1611
1622
.
10.
Dai
,
Y. Z.
, and
Chiang
,
F. P.
, 1992, “
Strain Path and Surface Roughness
,”
Mech. Mater.
0167-6636,
13
, pp.
55
57
.
11.
Aleksandrov
,
S. E.
,
Vilotic
,
D.
,
Goldstein
,
R. V.
, and
Chikanova
,
N. N.
, 1999, “
The Determination of the Workability Diagram
,”
Mech. Solids
0025-6544,
34
, pp.
118
125
.
12.
Fox
,
R. W.
, and
McDonald
,
A. T.
, 1978,
Introduction to Fluid Mechanics
,
Wiley
,
New York
.
13.
Azushima
,
A.
, and
Sakuramoto
,
M.
, 2006, “
Effects of Plastic Strain on Surface Roughness and Coefficient of Friction in Tension-Bending Test
,”
CIRP Ann.
0007-8506,
55
(
1
), pp.
303
306
.
14.
Han
,
H.
, 2002, “
The Validity of Mathematical Models Evaluated by Two-Specimen Method Under the Unknown Coefficient of Friction and Flow Stress
,”
J. Mater. Process. Technol.
0924-0136,
122
, pp.
386
396
.
15.
Becker
,
R.
, 1998, “
Effects of Strain Localization on Surface Roughening During Sheet Forming
,”
Acta Mater.
1359-6454,
46
, pp.
1385
1401
.
16.
Osakada
,
K.
, and
Oyane
,
M.
, 1970, “
On the Roughening Phenomenon of Free Surface in Deformation Process
,”
Trans. Jpn. Soc. Mech. Eng.
0375-9466,
36
(
286
), pp.
1017
1022
.
17.
Yamaguchi
,
K.
,
Takakura
,
N.
, and
Fukuda
,
M.
, 1987, “
FEM Simulation of Surface Roughening and Its Effect on Forming Limit in Stretching of Aluminium Sheets
,”
Proceedings of the Second International Conference on Technology of Plasticity
,
K.
Lange
, ed.,
Springer
,
Stuttgart, Germany
, Vol.
2
, pp.
1267
1274
.
You do not currently have access to this content.