Experimental and numerical characterization of friction in high temperature forming process

Experimental and numerical characterization of friction in high temperature forming process
Engineering for the Information Society and Sustainable Development
The host institution is the Faculty of Engineering of the University of Deusto. The research will be carried out within the Applied Mechanics research group: https://www.deusto.es/cs/Satellite/deustoresearch/en/home/centres-teams-and-researchers/research-teams/applied-mechanics-1/equipoinvestiga?cambioidioma=si Applied Mechanics is a young research group composed by experienced and enthusiastic researchers whose main objective is the application the latest advances in mechanical engineering for human and society development. Applied Mechanics develops focuses in four main research areas: • Advanced Industrial Processes • Transport Electrification • Plasma Characterization for industrial and scientific applications • Advanced Materials Behaviour The research project proposed will be related to the Advance Industrial Processes and Advanced Materials Behaviour research lines.
MSc in Mechanical Engineering, Materials Science and Engineering, Process Engineering. Knowledge of materials behaviour (metals), metal forming processes, laboratory testing, Tribology. Experience in numerical simulation (Finite Element Method) Technical and computational skills, interpersonal skills, Capable of working independently and enjoys collaborating in team environments.
  • Information Sciences and Engineering (ENG)
The research project proposed is the continuation of the PhD Thesis of Alberto Murillo (March 2019), and its objective is to reduce the impact in terms of energy consumption, waste generation, and natural resources depletion of the hot forming process in the manufacturing of seamless tubes. Improving this manufacturing process is a demanding challenge only achievable by means of knowledge and technology. Therefore, this proposal considers using the latest advances in laboratory testing added to complex numerical simulations to improve wear and friction conditions of this process. The expected outcomes: • Reduction of energy consumption • Improving product quality, which means reducing rejections, raw material, waste generation, … • Reduction of wear of the tools For the success of the research two partners will be involved. Tubos Reunidos Industrial s.l.u. (industrial partner), and the LAMIH institute from the University of Valenciennes, in France. The proposal consists of two main tasks. On the one hand, the development of a complex FE model of the seamless tubes manufacturing process, carried out in the University of Deusto. On the other hand, a set of tribological tests, that will be carried out in the LAMIH institute, in Valenciennes. Finally, the information gathered from both, the model and the experimental work will be used for characterizing and improve the contacts conditions, leading to the proposal of relevant actions to be implemented in the industrial process.

EXCELLENCE OF THE HOST RESEARCH UNIT

– Murillo-Marrodan, A., Garcia, E., & Cortes, F. (2018). A study of friction model performance in a skew rolling process numerical simulation. International Journal of Simulation Modelling, 17(4), 569-582. doi:10.2507/IJSIMM17(4)441. IF= 1.825 (Q3 Engineering) – Murillo-Marrodán, A., Puchi-Cabrera, E. S., García, E., Dubar, M., Cortés, F., & Dubar, L. (2018). An incremental physically-based model of P91 steel flow behaviour for the numerical analysis of hot-working processes. Metals, 8(4) doi:10.3390/met8040269. IF = 2.259 – García, E., Méresse, D., Pombo, I., Dubar, M., & Sánchez, J. A. (2016). Role of frozen lubricant film on tribological behaviour and wear mechanisms in grinding. International Journal of Advanced Manufacturing Technology, 82(5-8), 1017-1027. doi:10.1007/s00170-015-7397-3. IF = 1.568. – García, E., Sánchez, J. A., Méresse, D., Pombo, I., & Dubar, L. (2014). Complementary tribometers for the analysis of contact phenomena in grinding. Journal of Materials Processing Technology, 214(9), 1787-1797. doi:10.1016/j.jmatprotec.2014.03.026. IF = 2.236 – García, E., Méresse, D., Pombo, I., Harmand, S., & Sánchez, J. A. (2014). Identification of heat partition in grinding related to process parameters, using the inverse heat flux conduction model. Applied Thermal Engineering, 66(1-2), 122-130. doi:10.1016/j.applthermaleng.2014.01.048. IF = 2.739
– Mejora del Proceso de Perforado de Tubos sin Costura a través de Simulación Avanzada y Sensorización (TUBEST). PUE 2019-07 – (Project Unviersidad-Empresa of the Basque Goverment, 2019). Budget: 42.018,04€ – Simulación del proceso de calibrado de tubos sin costura TR2019. Hazitek Colaboratiivo with Tubos Reunidos, from Basque Goverment, 2019). Budget: 28.000,00€ – A2PBEER. European Commissioon unde the FP7. Contract number: theme[eDb.nmp.2013-3]. 2014-2015.Budget: 6.500.000,00 € – CAMEL-MCG. European Commission under the FP7. Contract number: SME-2010-1-261980 2010-2012. Budget:1.363.328,00€

INTERDISCIPLINARY COLLABORATION

The proposed project is an interdisciplinary topic within the field of industrial engineering. The expertise of the researchers of the Applied Mechanics research team is mainly focussed in the analysis and simulation of manufacturing processes and material behaviour. However, this project requires knowledge of tribological issues at high temperatures and elevated contact pressures, which is one of the expertise topics of the LAMIH institute. Therefore, the union of the knowledge of the University of Deusto and the University of Valenciennes will give as a result a project that comprises the whole aspects of the problem; from the process itself, passing through its simulation, up to the experimental study of friction and wear.
Yes. Please refer to the section addressing the international co-direction envisaged.
As mentioned, this proposal has to face several aspect among the industrial engineering. On the one hand, there is all the know-how related to the industrial process itself. This part, is supported by the industrial partner, Tubos Reunidos s.l.u. On the second hand, there is an important research area related to the numerical simulation of manufacturing processes in high temperature forming process for metals. The expertise of the Applied Mechanics research team has been proved through the years, as the projects and articles mentioned above show. And finally, the tribological aspect requires knowledge related not only to the tribology itself, but also know-how on experimental characterization of friction conditions. Here is where the expertise of the LAMIH institute makes the project stronger and able to success.

INTERNATIONAL COLLABORATION

The proposed PhD topic is aligned with the Key Enabling Technologies of H2020 priorities. In particular, this proposal is fully linked to the Energy-efficient buildings, Factories of the Future, and Sustainable Process Industries (SPIRE). Factories of the Future intends to increase the competitiveness of industries by the application of technology and knowledge to industrial processes. In this way, the proposed topic for PhD considers the use of TICs and advance experimental media to improve process performance and quality. The expected result is to improve competitiveness of the industry by directing its production process towards sustainability in terms of energy and raw material consumption, as well as reducing waste disposal. In sum, the proposal responds to to Europe’s concerns to create jobs, and address problems of energy and resource efficiency.
As mentioned, the proposal presented takes into account the active participation of the LAMIH institute, of the University of Valencinnes, France. The relationship between the LAMIH institute and the scientist in charge started in 2013 and has grown to a strong collaboration through the years, as can be seen in the articles related in the “EXCELLENCE OF THE HOST RESEARCH UNIT” section. This international partner is a leading institution in the study and characterization of friction, especially in hot forming processes (which is the case of the proposal). In addition to its know-how in the field of tribology on extreme conditions, they will contribute with the laboratory equipment of their facilities of the TRIBology in EXtrem conditions platform which in some cases is unique in Europe for the study of friction and wear at high temperature: Warm and Hot Upsetting-Sliding Test (WHUST), TRIBOLAB and associated metrology are the main devices that will be used in the experimental part of the work. Therefore, taking into account the relevance of the experimental work to be developed the international “co-tutelle” envisaged, since the student will spend long periods of time in the University of Valencienes and in the University of Deusto.

INTERSECTORAL COLLABORATION

The research project will be cofinanced by the industrial partner Tubos Reunidos Industrial s.l.u. This company is a research collaborator of the University of Deusto on several projects (as can be seen in the presented projects), a relationship that started in 2016, wiht the PhD thesis of Alberto Murillo. This company is fully committed with the project, since the results will be applied to its process contributing to enhance its production quality, performance, and know-how. THe company will feed the process with priceless process experience and data, as well guidanec through the research, testing materials and financial support. The expected finance to be given is 11.000,00€.
Industrial doctorate is not envisaged since the programme requires the researcher to be hired by the University of Deusto. However, the industrial partner will be involved in the research and training of the PhD student since the beginning.

IMPACT

The contribution of the proposed topic for the partners is very important. It must be taken into account that the proposed problem to research has been pointed out by the industrial partner together with the University of Deusto. Therefore, it can be understood that the topic is of main interest in the industry nowadays. In addition, as it has been explained previously, the results of the research will be a serial of improvements to be implemented directly in the industrial process. Therefore, the exploitation of the project by one of the stakeholders is clear and evident. They are going to profit from the knowledge generated to improve their industrial process, making it more efficient and competitive. However, it is important also to consider the scientific aspect of the research. The understanding of friction and wear in extreme conditions is a topic of greatest interest within the research community given the difficulty to obtain relevant and reliable data. From the research to be develop it is expected to publish at least two or three indexed (JCR) articles, as well as international conference, ESAFORM could be an interesting forum. This way, the scientific community could confirm the contributions obtained during this research project.

INNOVATION

The main innovative aspect of this proposal is the use combined of complex numerical simulation (University of Deusto) with the experimental platform and know-how of the LAMIH institute, for a real industrial process, that of Tubos Reunidos Industrial, s.l.u. It must be taken into account that the TRIBology in EXtrem conditions platform from the LAMIH is almost unique in Europe for the study of friction in extreme conditions. This added to the numerical simulation fo the process gives as a result a huge combination of possibilities: – find new friction models – identify wear patterns – include the effect of tool materials – understand the effects of process parameters (relative velocities, pressures, and temperatures) All these aspects, are to be researched still, because there has not been the possibility to combine the three aspects mentioned above: complex simulation, advance experimental techniques, and industrial process

INCLUSION

The proposed topic gives the chance for the development of the society within a trend of overcoming long-term limitations. The effect of industrial manufacturing has been usually seen negatively, becosue of their impacts. However, most societies need from industrial products for its development. Improving a process which is at the beginning of the value chain is essential for the advance of the society towards a common good. In addition, the rational use of energy and raw materials benefits now only the environment but also the possibility of reducing the injustices between industrialised and poor nations. Deusto is committed to social justice and inclusion. It recognises gender equality as a key driver for sustainable development, inclusive growth and academic opportunity for women. Moreover, to seek real inclusion for people with specific support needs, the project will ensure equal rights and opportunities with respect to access to the programme and the acquisition of skills expected to achieve the PhD.