Investigation On The Frictional Behaviour Of Aluminium Aa4032 Alloy Using Experimental And Numerical Approach

Abstract

Nowadays, Aluminum 4032 Alloy And Different Non-Ferrous Material Combinations Are Widely Used For Applications Such As Car Component Production, Airplane Industry And Civil Engineering, Where Lightweight Materials Are Required. In The Industrial Metal Working Operations, Most Of The Time, To Reduce Friction, Metal Forming Industries Have Been Using Unrecommended Lubricant During Metal Alloys Forged To Various Components. However, For Metallic Alloys A Realistic Friction Factor Must Be Specified At The Die-Work Piece Interface In Order To Obtain Accurate Metal Flow. The Friction Factor Of The Different Metal Alloy Shows Different Behavior Under Different Metal Forming Processes. The Aim Of This Research Was To Investigate Frictional Behavior And Select Suitable Lubricant For Processing Of Aluminum 4032 Alloy Using Ring Compression Test. The Investigation Was Structured Into Two Parts. The First Part Was To Study Experimentally The Effects Of Surface Roughness Of Work Piece On The Friction Factor. The Experiment Was Performed Using 1.5 ??M, 2.5 ??M And 3.5 ??M Work Piece Roughness To Understand How Various Surface Roughness Affects The Friction Behavior During Dry Conditions. The Second Experimental Study Was Conducted As The Effects Of Various Lubricants On The Friction Factor By Varying The Lubricating Conditions With Respect To Selected Surface Roughness At Lower Values Of Interface Friction. In Order To Know The Friction Behavior Of Aa 4032, A Number Of Lubricating Conditions, Including Palm Oil, Grease, And Emulsion Oil Were Examined. For Both Experiment, Deform-3d, A Commercial Finite Element Simulations Were Used To Analyze The Effects Of Various Surface Roughness And Lubricating Conditions On The Interface Friction Factor, In Order To Evaluate Frictional Behavior Of Aluminum 4032 Alloy Effectively. Ring Compression Test Results Indicate That The Use Of Smoother Surface Roughness Of Work Piece Has Reduced The Friction Factor During Dry Condition. In Addition, The Friction Factor Was Determined For Various Lubricating Conditions, And Palm Oil Is Found To Be A Suitable Lubricant For Aa 4032 During Cold Forging. Effects Of Various Surface Roughness And Lubricating Conditions On The Interface Friction Factor, Obtained By Finite Element Simulations Are In A Good Agreement With The Experimental Data.