Mesoscopic comparison of interface tool/workpiece for simulation by FEM of EN AW 1350 bulk forming alloy

¹ Laboratoire de Mécanique Industrielle, Université Badji Mokhtar, BP 12, 23000 Annaba, Algeria
² Laboratoire de Mécanique Appliquée des Nouveaux Matériaux, Université 8 mai 1945, BP 401, 24000 Guelma, Algeria
³ BATir, Université Libre de Bruxelles, Avenue Roosevelt 87, Bruxelles 1050, Belgique
⁴ LaMCoS, INSA de Lyon, 20 avenue A. Einstein, 69621 Villeurbanne Cedex, France

^a Corresponding author: fakhreddinekherouf@gmail.com

Received: 10 August 2013
Accepted: 18 November 2014

Abstract

This paper presents an improved numerical simulation of bulk metal forming processes. It takes into the account the advanced formalism of large displacements and large deformations. Also, the interface workpiece formalism is considered. Metallographic studies are conducted to determine the evolution of the micro hardness as a function of annealing time and that to characterize accurately the plastic range of aluminum alloy for a range of plasticity 160%. The obtained results of metallographic studies are used to simulate a upsetting under the friction law of the plastic wave. A numerical simulation by FEM of bulk forming alloy is carried out by replacing the real profile of the surface roughness by two triangular profiles, the first has the same height as the real profile and the second has the same area then by a trapezoidal profile of the same height. The obtained results are compared to Challen and Oxley results in order to validate the triangular profile used in the friction model of plastic wave.