Wear, 34 (1975) 77 - 84 77

0 Elsevier Sequoia S.A., Lausanne - Printed in the Netherlands

R, AND THE AVERAGE EFFECTIVE STRAIN OF SURFACE

ASPERITIES DEFORMED IN METAL-WORKING PROCESSES*

N. BAY, T. WANHEIM and A. S. PETERSEN

Department of Mechanical Processing of Materials, A.M.T., Technical University of
Denmark (Denmark)
(Received February 20, 1975)

Summary

Based upon a slip-line analysis of the plastic deformation of surface

asperities, a theory is developed determining the R,-value (c.1.a.) and the
average effective strain in the surface layer when deforming asperities in
metal-working processes. The ratio between R, and R,,,, the R,-value after
and before deformation, is a function of the nominal normal pressure and
the initial slope y. of the surface asperities. The last parameter does not
influence R, significantly. The average effective strain E in the deformed sur-
face layer is a function of the nominal normal pressure and yo. E is highly
dependent on yo, F increasing with increasing yo. It is shown that the R,-
value and the strain are hardly affected by the normal pressure until interact-
ing deformation of the asperities begins, that is until the limit of Amonton’s
law is reached. After that R, decreases and the strain increases rapidly with
the normal pressure, R, approaching zero whilst F approaches a limiting
value depending on the initial slope of the asperities.

Nomenclature

Q-n nominal friction stress

9 nominal normal pressure
equivalent yield stress
I: yield stress in pure shear
R, c.l.a.-value
R 00 initial R,-value
t distance between ridges
2 vertical displacement of tool
Ad area of the deformed zone
A area of the instantaneous deformation zone
m friction factor

*Paper presented at the Tribology Session of the Eighth Israel Conference on

Mechanical Engineering, Technion, Haifa, 23 - 24 September, 1974.
78

a! ratio between real and apparent area of contact

P ratio between R, and RoO
F average effective strain in the deformed zone
Em average effective strain in the instantaneous deformation zone
Y slope of the asperities

1. Introduction

Friction conditions between tool and workpiece in metal-working

processes have a great influence on factors such as force, mode of deforma-
tion, properties of the finished specimen and the resulting surface roughness.
Wanheim, Bay and Petersen [l] have developed a friction theory for metal-
working processes:
7, =mak (1)
Using the slip-line theory for investigation of the plastic deformation of sur-
face asperities, the ratio (Ybetween real and apparent area of contact was
determined as a function of the nominal normal pressure q/2k and the fric-
tion factor m, Fig. 1.
Using eqn. (l), 7,/k was determined as a function of q/2k and m. Slip-
line analysis makes it possible to determine the R, (c.1.a.) value of a metal-
worked specimen as a function of the initial R,-value, Rae, of the specimen,
the normal pressure and the friction factor. This is described in the present
paper. A theory for the average effective strain E of the deformed asperities
is developed, determining c and thereby the hardness of the surface layer as a
function of the normal pressure and the initial slope of the asperities for the
casem=O.

2. Geometrical variation of ridges

To calculate the R,-value and the average effective strain, it is necessary

to determine the geometry of the surface asperities as a function of the
initial geometry. Assume the same initial geometry as earlier [l] , that is
ridges symmetrical in the plane of view and infinite in depth, Fig. 2, which
means a situation of plane strain. Confined to the ‘case of m = 0, the propos-
ed [l] development of the slip-line fields with increasing a! is shown in Fig. 3.
The inclination of the free surface changes when being deformed. The initial
angle of inclination is y. but in Fig. 3(a) the free surface consists of two
planes with different inclinations namely +yoand TV. In Fig. 3(b) (a! = al) the
inclination has increased to r1 for the whole free surface. By the law of
volume constancy, r1 and 01~are given by:
3tanyo-4+223tanyo+4
tanyi = (2)
4-tan70
1 + tarry1
e1 =3+tan~l
 79

00 1.0 2.0 3.0 40 6

Fig. 1. The real area of contact as a function of the nominal normal pressure and the
friction factor.
Fig. 2. Initial geometry of surface asperities.

“t
bLJ
0

“t
8 0

“t
b
0
Ii3
(a)
0

“t
b (b)
Ut

“t
b
Fig. 3. Development of slip-line fields and corresponding hodographs with increasing Q!
for M = 0.

For (Yincreasing from a1 to 0~2,~ decreases from y 1 to 7 2. From the

hodograph, Fig. 3(c), it is seen that the bottom of the valley moves upwards
at the same velocity ut as the surface moves downwards. The volume
constancy then gives:
80
8 tanyi (1 + tanyi)
tanyz =
(3 + tanyi)2
1 (3)
ffp =-
2

Similarly the hodograph corresponding to Fig. 3(e) shows that the bottom
moves upwards at the same velocity ut as the surface moves downwards and
gives:
5tany2-12+4J5tany2+9
tanys =
8--any2
(4)
3 + tanys
(Y -
3 -5+tany3

The hodograph in Fig. 3(g) shows that the bottom moves upwards at a
velocity twice the downwards velocity of the surface ut. The law of volume
constancy then yields:
12 tan-r3(2 + tany3)
tarry, =
(5+ tw312
(5)
2
a 4=-
3
For LY> e4, y remains constant and equal to y4.

3. Determination of R,

A theoretical determination of the resulting surface geometry of a

metal-worked specimen has so far not been possible, but based upon the
results found by the slip-line theory [ 11, for the case of zero friction it is
possible to determine the R,-value (c.1.a.) as a function of y. and q/2k. As
shown in section 2 the very simple initial geometry chosen will result in a
relative simple geometry of the deformed ridges, and thereby:
R,
aO Eo(l -e (6)
’ =R- =
where RaO is the R,-value of the undeformed ridges and is given by:

R 00 =-
t t=wo
8
Corresponding values between OLand y are determined by eqns. (2) - (5).
To determine p as a function of q/2k, the relationship between (Yand
q/2k shown in Fig. 1 is used. Figure 4 shows the p-value plotted as a func-
tion of the nominal normal pressure with +yoas a parameter. It is seen that p
is nearly independent of y. which seems reasonable. Furthermore p only
decreases slightly with increasing q/2k as long as q/2k < 0.6, whereas p
decreases rapidly and approximately linear with q/2k in the case of q/2k >
 81

Fig. 4. p = RJR,, as a function of q/2k and 70.

1.0
09
OS
07
06
05
QL
0.3
0.2
0.1
4
00
- -0.0 1.0 2.0 30 40-z
Fig. 5. p = RJR,0 as a function of q/2k and m; yo = 5’.

0.6. The reason for this change is that the slip-line field reaches the bottom
of the ridge, Fig. 3, which means that the bottom begins to rise. At q/2k =
2.4 the &-value has decreased to 10% of the initial value and at q/2le-values
higher than 3.0, R, is vanishing.
The analysis is based upon an assumption of zero friction between tool
and specimen, but it is reasonable to assume that the relationship between p
and (Yis approximately unaffected by the friction factor. Under this assump-
tion the relationship between p, q/2k and m has been determined (Fig. 5)
for the case of y. = 5”, using Fig. 1 and eqn. (6).
As seen, p is nearly independent of q/2k for small q/2k values, for
medium q/2k-values, p decreases approximately linearly with q/212 and for
large q/2k-values, p approaches zero. Furthermore p decreases with increas-
ing friction factor corresponding to the fact that increasing friction factor
causes the real area of contact to increase.

4. Determination of the average effective strain

A theoretical determination of the average effective strain in the sur-

face layer of a metal-worked specimen, that is in the deformed zone of the
ridges, is important. It is necessary to know the strain in order to use the
friction theory [l] in practice and knowledge of the strain also provides
information concerning hardness and wearability of the specimen surface.
82

L t -i
Fig. 6. Notation.

Bay and Wanheim [2] have for the case of cone indentation described a
method to determine the average effective strain in the deformation zone.
The theory was based upon the law of conservation of energy and the same
method of analysis is applied here.
In the following analysis the notation shown in Fig. 6 is used and again
confined to the case of zero friction, that is m = 0. Compressing the tool a
distance z into the surface asperities results in an externally supplied energy
W, given by:

The internal energy dissipation Wi is given by:

integrating over area since plane strain deformation was assumed. Conserva-
tion of energy now leads to We = Wi that is:

where E is the average effective strain in the deformed zone Ad of the

specimen. Replacing integration by summation and looking only at a step-
wise deformation, gives:

(7)

where
AZi Zi-2i-l
-=
t t
The correspondence between the i-value and the stage of deformation is so
chosen that i = 1, 2, 3, 4, 5, . . . corresponds to stage b, d, f, h, k, .. . (see
Fig. 3). Geometrical considerations now give AZi/t (see appendix).
To determine the real strain increment the Ad,-values which should be
inserted in eqn. (7) are given by:
Adi = Ai for i = 1,2

Adi = Az for i > 2

 83

Fig. 7. F as a function of q/2& and 70.

where Ai is the area of the instantaneous deformation zone. The reason for
this is that the deformation zone for i > 2 is reduced and everywhere enclos-
ed in the deformation zone present at stage 2, which is not quite obvious
from Fig. 3 but proves true when making a closer investigation. Al and A2
are found by geometrical considerations (see appendix). The values of
(q/2k), to be inserted in eqn. (7) are found from Fig. 1. Since the deformed
zone of the ridges in stage 1, Fig. 3, is enclosed too in the deformation at
stage 2, the average effective strain in the deformed zone is now given by:

- -
Ei =tZl -?2+iA& (i>2)
2

It should be noted that c, in the case of i > 2 differs from the average effec-
tive strain E, in the instantaneous deformation zone, E, being greater than
Ei since the deformation zone is reduced for i > 2. An exact determination of
E, is rather complicated, since it involves considerations concerning the
strain distribution in the deformation zone, and will therefore not be
attempted here. Slip-line fields for i > 2 show that the deformation zone is
steadily reduced with increasing cu; assuming a uniform strain distribution
in the instantaneous deformation zone, the following expression for e,
could be used:
= fi (i = 1,2)
Emi

Emi = Em,i-1 + AG * A.2fi._ (i > 2)

A3 and A4 are determined by gekmetrical considerations (see appendix)

whereas Ai for i > 4 is measured on the slip-line field using a planimeter.
 yo=i 5’

yQ=lO’
- *
x0=5

00 ’
00 10 20 30

Fig. 8. E, as a function of q/2k and 70.

Figure 7 shows the relationship between the average effective strain f in the
deformed zone of the specimen, q/2k and yo. It is seen that E is approxima-
tely constant for q/2k less than about 1.3, that is as long as the deformation
zones are isolated and Amonton’s law is obeyed. For q/2k > 1.3, E suddenly
increases with q/212 approaching a limiting value depending on 70. The
reason for the sudden increase in E is that the deformed zone does not
increase further. It is also seen that < increases with increasing y. as expected.
In Fig. 8 the average effective strain E, in the instantaneous deforma-
tion zone is plotted as a function of q/2k and 70. The tendencies are the
same as for the E-curves, the only difference being that E, increases to a
greater extent than E.

5. Appendix
AZ,
-=
tan70 (1 + twd A22
-=
tiny1 (1 -taw,)

t 4(2+tanyl) ’ t 2 (3 + tanyi)2 ’

A23
-=
tw3 (1 + tav3) A24
-=
taw, (1 - t=v31

t 2 (5 + tanQ ’ t 3 (5 + tanys)s ’

Azi = (I- hi-A2 - (1 - cd2 tan74 (i > 4)

t 4
Ai l+tany,
-= [(7T-l)tanyi +3+n1,
t2 4 (3 + tany,)2
A2 Z+n-tany2 A3 11 + 477- h73 (2 + tm73)
-= -=
t2 16 ’ t2 4 (5 + tany,)2 ’

A4 3+n-tany4
-=
t2 36 ’

1 T. Wanheim, N. Bay and A. S. Petersen, Wear, 28 (1974) 251.

2 N. Bay and T. Wanheim, Int. J. Prod. Res., 12 (1974) 195.