Cavity Design for Surface Textured Sheets in Metal Forming

It is estimated that 23 % of the global energy consumption is attributable to friction between surfaces and subsequent wear. Accordingly, improvements in the tribological characteristics in industrial procedures hold considerable promise. The modification of tribological performance within the context of sheet metal forming operations using texturing is a common objective. The authors have previously shown that the geometry and distribution of cavities, in conjunction with the dominant load collective, have a considerable impact on the extent to which tribological performance can be enhanced. Accordingly, this study proposes a systematic methodology for the design of cavities on the surface of sheet metals, with the objective of optimising tribological properties. Consequently, the fundamental rheological processes underlying surface texturing in lubricated sheet metal forming operations are being examined using computational fluid dynamics. The optimal cavity design is determined by the maximum reduction in the coefficient of friction. Based on these findings, the influence of lubricant reservoirs and the generation of hydrodynamic pressure on the cavity dimensions and distributions are discussed by correlating a laminar flow analysis with the previous findings. It is demonstrated that cavity parameters, specifically coverage ratio and lubrication clearance, have the most significant impact on friction reduction.