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Research Article | Open Access

Experimental and modelling study of interaction between friction and galling under contact load change conditions

Xiao YANG1, Yiran HU1, Lemeng ZHANG1, Yang ZHENG1, Denis J. POLITIS2, Xiaochuan LIU3, Li-liang WANG1( )
Department of Mechanical Engineering, Imperial College London, London SW7 2AZ, UK
Department of Mechanical and Manufacturing Engineering, University of Cyprus, Nicosia 1678, the Republic of Cyprus
School of Mechanical Engineering, Xi’an Jiaotong University, Xi’an 710049, China
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Abstract

The galling process remains one of the least understood phenomena in metal forming. The transfer of material from a work-piece onto the tool surface can cause an evolutionary increase in friction coefficient (COF) and thus the use of a constant COF in finite element (FE) simulations leads to progressively inaccurate results. For an aluminium work-piece, material transfer, which has history and pressure dependency, is determined by a dynamic balance between the generation and ejection of wear particles acting as a 'third body’ abrasive element at the contact interface. To address this dynamic interactive phenomenon, pin-on-disc tests between AA6082 and G3500 were performed under step load change conditions. The COF evolutions, morphologies of the transfer layer and its cross-section were studied. It has been found that contact load change will disequilibrate and rebuild the dynamic balance and high load will increase the generation and ejection rate of third body and vice versa. Moreover, based on the experimental results, an interactive model was developed and presented to simulate the dynamic formation process of the aluminium third body layer under load change conditions, enabling multi-cycle simulations to model the galling distribution and friction variation.

Keywords

gallingmetal formingload changeinteractive friction modelAA6082 aluminium alloy

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Friction
Volume 10 Issue 3,
March 2022
Pages 454-472
DOI: 10.1007/s40544-021-0531-3
Cite this article:
YANG X, HU Y, ZHANG L, et al. Experimental and modelling study of interaction between friction and galling under contact load change conditions. Friction, 2022, 10(3): 454-472. https://doi.org/10.1007/s40544-021-0531-3

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Received: 23 February 2021
Revised: 23 April 2021
Accepted: 27 May 2021
Published: 09 July 2021
© The author(s) 2021

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