<p>In sheet metal forming processes, friction has decisive effects on the strain distribution in the deformed sheets and the quality of the final product due to the large surface/thickness ratio of the blank sheets. It is well known that friction in sheet forming operations is dependent on local contact conditions such as surface roughness, contact pressure and sliding velocity. Adding complexity to this frictional behavior, some rolled sheets have oriented surface roughness and show considerable frictional anisotropy. A constant friction model without consideration of these relevant phenomena is regarded as the reason why sheet metal forming simulations often fail to produce satisfying results despite the well developed material models. </p> <p>To develop a friction model which considers both of the varying conditions of local contact and the frictional anisotropy was the aim of this thesis. For this purpose, the analysis method of the friction test (draw-bend test) had to be examined for the capability to evaluate these parameters independently. Through careful study using finite element simulations, it was found that the conventional method has shortcomings in addressing pressure dependent friction due to the pressure non-uniformity existing in the test. Therefore, a new analysis method, which can evaluate pressure dependency of a friction coefficient, was developed. In the new method, contact pressure maps obtained from simulations were included in the analysis of test data.</p> <p>The new analysis method was applied to friction measurement of aluminum sheets with known anisotropic mill finish, and friction coefficients were obtained as functions of contact pressure, sliding velocity and sliding direction. In the obtained friction model, a friction coefficient is a continuous surface over the domain of contact pressure and sliding velocity. Lastly, the new friction model was implemented into a finite element code and the model was validated through circular cup drawing experiments and simulations. The comparisons showed good agreements in the aspects of punch force, cup size and failure location. Thus, the newly developed model can accurately predict the effects of anisotropic friction in sheet metal forming processes. </p> / Thesis / Doctor of Philosophy (PhD)

Dissimilar metals joining have been used in many industry fields for various applications due to their technique and beneficial advantages, such as aluminum-steel and magnesium-steel joints for reducing automobile weight, aluminum-copper joint for reducing material cost in electrical components, steel-copper joints for usage in nuclear power plant, etc. The challenges in achieving dissimilar joints are as below. (1) Big difference in physical properties such as melting point and coefficient of thermal expansion led to residual stress and defects. (2) The miscibility issues resulted in either brittle intermetallic compound layer at the welded interface for miscible combinations (such as, aluminum-steel, aluminum-copper, aluminum-titanium, etc.) or no metallurgical bonding for immiscible combinations (such as magnesium-copper, steel-copper, etc.). For metallurgical miscible combinations, brittle intermetallic compounds formed at the welded interface created the crack initiation and propagation path during deformational tests. (3) Stress concentration appeared at the welded interface region during tensile testing due to mismatch in elastic properties of dissimilar materials. In this study, different combinations of dissimilar metals were joined with friction stir welding. Lap welding of 6022-T4 aluminum alloy/galvanized mild steel sheets and 6022-T4 aluminum alloy/DP600 steel sheets were achieved via friction stir scribe technology. The interlocking feature determining the fracture mode and join strength was optimized. Reaction layer (intermetallic compounds layer) between the dissimilar metals were investigated. Butt welding of 5083-H116 aluminum alloy/HSLA-65 steel, 2024-T4 aluminum alloy/316 stainless steel, AZ31/316 stainless steel, WE43/316 stainless steel and 110 copper/316 stainless steel were obtained by friction stir welding. The critical issues in dissimilar metals butt joining were summarized and analyzed in this study including IMC and stress concentration.

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State highway agencies have an obligation to provide users with optimal surface conditions under various weather conditions throughout the year. A satisfactory pavement surface should exhibit good friction and texture depth to reduce roadway highway accidents. This is why friction is starting to receive increased attention in the pavement management process. There have been numerous research efforts by different countries and agencies to better understand the behavior of different friction testing devices and the influence of texture, speed, and other external conditions on their measurements. The first part of this thesis presents a research effort to compare and harmonize texture and skid resistance measurements taken with various devices on 24 pavement sections with a wide range of textures. Measurements were compared and the International Friction Index (IFI) calculated following PIARC and ASTM steps. The results revealed discrepancies in the IFI values calculated for the different devices, suggesting that the coefficients A, B, and C proposed by PIARC may need to be adjusted for each device considered before the IFI can be implemented by the surface properties consortium participating agencies. In this research the A, B, and C coefficients were then recalculated, and the predicted values of friction using these revised coefficients are presented. The coefficients developed were also used to obtain IFI values for high-friction surfaces (HFS). It has been found that under different conditions, different parameters and coefficients will result. It is strongly recommended equipment comparison experiments (like the NASA and Smart Road programs) continue to better determine the coefficients necessary for harmonization. HFS have emerged as viable high-friction pavement alternatives that mitigate the consequences of driver error, poor geometric alignment of the roadway, and insufficient friction at the tire-pavement interaction, especially during wet weather. This thesis presents a study of the HFS available in the U.S. market and their performance (friction and texture) in different applications, under different weather conditions, and in various locations. This thesis also presents the results of the benefit-cost analysis for the studied HFS. / Master of Science

published_or_final_version / Civil Engineering / Master / Master of Philosophy

The use of hot surface films for measuring skin friction is examined. It is shown that all existing theories, which neglect heat conduction within the substrate, are inadequate in predicting the variation of heat loss from the film with skin friction. A more physically realistic theory is presented which accounts for the conductive and convective heat transfer into the flow and also heat conduction within the substrate. This leads to a more general relationship between skin friction and heat loss from the film. Experiments conducted in flat plate laminar and turbulent boundary layer flow show that this relationship is more accurate than previous forms. The time and temperature dependence of the heat loss from the hot film are also explored theoretically and experi- mentally. The effect of surface misalignment of the film is shown to alter significantly the convective heat transfer. This effect is more pronounced in laminar flow than in turbulent flow. Using a glue-on hot film probe, calibrations relating the heat loss to skin friction were found to be different in laminar and turbulent flow. An experimental operating procedure for the use of hot surface films for measuring skin friction is proposed which significantly increases the accuracy of the technique.

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