This paper deals with the identification of an empirical equation for predicting free surface roughness evolution. The equation has been proposed elsewhere, and, in contrast to widely used equations, assumes that the evolution of free surface roughness is controlled by two kinematic variables, the equivalent strain, and the logarithmic strain normal to the free surface. Therefore, an experimental program is designed to account for the effect of the mode of deformation on free surface roughness evolution. Thin sheets of aluminum alloy A5052-O and pure copper C1220P-O alloys are used to conduct the experimental program. In addition, numerical simulation is performed to calculate the evolution of free surface roughness under the same conditions. Comparison of experimental and numerical results shows that the accuracy of the numerical results is good enough. Then, numerical simulation is extended to the domain in which no experimental results are available. Discrete functions so found are fitted to polynomials. As a result, continuous functions that represent the empirical equation for predicting free surface roughness evolution for A5052-O and C1220P-O alloys are determined. These equations can be used in conjunction with solutions to boundary value problems in plasticity for predicting the evolution of free surface roughness in metal forming processes.
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March 2018
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Identification of an Empirical Equation for Predicting Free Surface Roughness Evolution in Thin Sheets of Aluminum Alloy and Pure Copper
Tsuyoshi Furushima,
Tsuyoshi Furushima
Institute of Industrial Science,
The University of Tokyo,
4-6-1 Komaba,
Meguro 153-8505, Tokyo, Japan
e-mail: tsuyoful@iis.u-tokyo.ac.jp
The University of Tokyo,
4-6-1 Komaba,
Meguro 153-8505, Tokyo, Japan
e-mail: tsuyoful@iis.u-tokyo.ac.jp
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Hideki Sato,
Hideki Sato
Department of Mechanical Engineering,
Tokyo Metropolitan University,
Hachioji 192-0397, Tokyo, Japan
Tokyo Metropolitan University,
1-1 Minami-osawa
,Hachioji 192-0397, Tokyo, Japan
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Ken-ichi Manabe,
Ken-ichi Manabe
Department of Mechanical Engineering,
Tokyo Metropolitan University,
Hachioji 192-0397, Tokyo, Japan
e-mail: manabe@tmu.ac.jp
Tokyo Metropolitan University,
1-1 Minami-osawa
,Hachioji 192-0397, Tokyo, Japan
e-mail: manabe@tmu.ac.jp
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Sergei Alexandrov
Sergei Alexandrov
Institute for Problems in Mechanics
Russian Academy of Sciences,
Moscow 119526, Russia
e-mail: sergeyaleksandrov@yahoo.com
Russian Academy of Sciences,
101-1 Prospect Vernadskogo
,Moscow 119526, Russia
e-mail: sergeyaleksandrov@yahoo.com
Search for other works by this author on:
Tsuyoshi Furushima
Institute of Industrial Science,
The University of Tokyo,
4-6-1 Komaba,
Meguro 153-8505, Tokyo, Japan
e-mail: tsuyoful@iis.u-tokyo.ac.jp
The University of Tokyo,
4-6-1 Komaba,
Meguro 153-8505, Tokyo, Japan
e-mail: tsuyoful@iis.u-tokyo.ac.jp
Hideki Sato
Department of Mechanical Engineering,
Tokyo Metropolitan University,
Hachioji 192-0397, Tokyo, Japan
Tokyo Metropolitan University,
1-1 Minami-osawa
,Hachioji 192-0397, Tokyo, Japan
Ken-ichi Manabe
Department of Mechanical Engineering,
Tokyo Metropolitan University,
Hachioji 192-0397, Tokyo, Japan
e-mail: manabe@tmu.ac.jp
Tokyo Metropolitan University,
1-1 Minami-osawa
,Hachioji 192-0397, Tokyo, Japan
e-mail: manabe@tmu.ac.jp
Sergei Alexandrov
Institute for Problems in Mechanics
Russian Academy of Sciences,
Moscow 119526, Russia
e-mail: sergeyaleksandrov@yahoo.com
Russian Academy of Sciences,
101-1 Prospect Vernadskogo
,Moscow 119526, Russia
e-mail: sergeyaleksandrov@yahoo.com
1Present address: 293 Yoshida, Totsuka, Yokohama, Kanagawa 244-0817 Japan. Manuscript received September 28, 2016; final manuscript received December 1, 2017; published online January 25, 2018. Assoc. Editor: Yannis Korkolis.
J. Manuf. Sci. Eng. Mar 2018, 140(3): 034501 (6 pages)
Published Online: January 25, 2018
Article history
Received:
September 28, 2016
Revised:
December 1, 2017
Citation
Furushima, T., Sato, H., Manabe, K., and Alexandrov, S. (January 25, 2018). "Identification of an Empirical Equation for Predicting Free Surface Roughness Evolution in Thin Sheets of Aluminum Alloy and Pure Copper." ASME. J. Manuf. Sci. Eng. March 2018; 140(3): 034501. https://doi.org/10.1115/1.4038822
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