Evaluating the Relationships Between Surface Roughness and Friction Behavior During Metal Forming

The inhomogeneous distribution of surface asperities generated by deformation induces variability in the friction and initiates strain localizations during metal forming. The friction literature generally does not account for the strong influence localized variations in material properties have on the friction behavior. A prototype apparatus was developed that measures the friction behavior under simulated forming conditions and enables detailed characterization of the influences of the microstructure and the topographical conditions that occur under those conditions. The results demonstrate that the measurement system can resolve subtle real-time changes in the dynamic friction coefficient, and that a correlation could exist between the largest surface asperities and the largest variations in the measured friction coefficient.