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<p>In this work, through multi-scale cylindrical upsetting experiments, the influence of specimen size, original specimen surface roughness, and the surface roughness of the die on the size effect of friction was studied. Based on the Weierstrass–Mandelbrot (W–M) fractal function and finite element simulation, the micro-upsetting process with real surface topography was simulated, and a method for determining the friction factor of the contact surface under different surface roughnesses was proposed. The results showed that the size effect is significant under dry friction conditions, especially when the specimen size is less than 2.0&#xa0;mm. At the initiation stage, the influence of the initial surface roughness of the specimen on the actual contact ratio is dominant. As the reduction ratio increases, the change in the specimen size has a crucial influence on the actual contact ratio. The reduction in specimen size leads to a decrease in the actual contact area, ultimately resulting in a decrease in the contact friction force. This modeling method can provide technical references for multi-scale modeling theory and high-precision micro-part manufacturing.</p>

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Dry Friction Behavior during Plastic Deformation of a 6063 Al Alloy at Micro–mesoscopic Scale

  • 期刊论文

  • 发表日期：

    2025年9月10日

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  • Wei Zheng,
  • Xueheng Zong,
  • Juanjuan Han,
  • Guanghan Dang,
  • Liang Chen,
  • Shubo Xu

摘要

In this work, through multi-scale cylindrical upsetting experiments, the influence of specimen size, original specimen surface roughness, and the surface roughness of the die on the size effect of friction was studied. Based on the Weierstrass–Mandelbrot (W–M) fractal function and finite element simulation, the micro-upsetting process with real surface topography was simulated, and a method for determining the friction factor of the contact surface under different surface roughnesses was proposed. The results showed that the size effect is significant under dry friction conditions, especially when the specimen size is less than 2.0 mm. At the initiation stage, the influence of the initial surface roughness of the specimen on the actual contact ratio is dominant. As the reduction ratio increases, the change in the specimen size has a crucial influence on the actual contact ratio. The reduction in specimen size leads to a decrease in the actual contact area, ultimately resulting in a decrease in the contact friction force. This modeling method can provide technical references for multi-scale modeling theory and high-precision micro-part manufacturing.