Numerical Analysis of the Tribological Mode of Action in Cold Form-ing of Sinus Waved Surfaces Structures

Cold forming processes combine high material utilization with high energy and resource efficiency. Therefore they are of great importance in production engineering. Due to high loads and stresses, liquid and solid lubricants are used to successfully perform cold forming processes. Recent findings revealed the ecological, economic, and legislative ques-tionableness of these lubricants. The absence of lubricants would be a significant contribution to waste reduction in manufacturing processes and to the goal of the lubricant-free factory. The absence would lead to higher tribological loads which need to be compensated by either the tool or the workpiece. In this contribution a novel approach in struc-turing of workpieces by sinus curves as approximation of shot peened surface structures. It contains sinus curves for a determined surface structure. These sinus curves are varied in amplitude and wavelength factor. Hereby, an determinis-tic modeled surface structure is researched regarding contact area during surface smoothing, contact stresses, and fric-tion force. In future work the results will enable further research on the ideal surface structure for dry metal forming.