A friction model for microforming

For the simulation of metal forming processes, input data relating to the tool–workpiece interface is necessary. For microforming applications, this input data becomes very much more critical and traditional methods are not realistic. This paper describes an approach that seeks to describe friction by modelling the geometric surface roughness of the tool. This finite-element-based model has been validated experimentally in terms of loads and metal forming using the ring test and actual surface measurements. It enables more accurate and also more flexible modelling of friction.