Head of section: A. Dubois

Members

Permanent members: F. Bechet Associate Prof. 100% L. Dubar Prof. (Head of TEMPO) 100%

M. Dubar Prof. 100% A. Dubois Prof. 100%

C. Foucart Secretary 50% T. Garçon Assistant Engineer 50%

J.-D. Guérin Associate Prof. 100% D. Lochegnies Prof. 100%

P. Moreau Research Engineer 100% J.-J. Santin Associate Prof. 100%

M. Watremez Associate Prof. 100%

Post-Doc: C. Hubert (since 07/10)

Current PhD Thesis: D. Barbier (Industrial grant, Vallourec, since 05/10) J. Camus (Industrial grant, Myriad, since 09/10)

G. Collemiche (Industrial grant, Bosch, since 09/06) R. El Cheikh (Academic grant, since 10/09)

M. Fleurant (Industrial grant, Myriad, since 09/10) A. Heussaf (Industrial grant, Daimler, since 09/09)

D. Meresse (Academic grant, since 10/07) M. Wanassi (Academic grant, since 10/09)

Others: G. Leclercq (Research Engineer, since 05/10) D. Montoya (Engineer, since 11-10)

Main results for nov. 2008-nov. 2010 period

PhD Thesis 5

HDR (French post-doctoral degree to supervise PhD Student) -

Patents -

International National

Books and Book chapters - 1

Editorial activities (or Contributions to Conferences and

Workshops or Edited Work) 4 3

Papers 19 -

Conferences with proceedings and scientific committee 12 -

Other Conferences 2 1

Main events Guest member of International Cold Forging Group (L. Dubar)

Cotutelle thesis between the University of Kaiserslautern and the University of Valenciennes,

with a collaboration of the Fraunhofer Institute ITWM for Technical and Industrial

Mathematics de Kaiserslautern, The Mathematics Department of the University of

Kaiserslautern, the EDP team of the LAMAV and the MSM team in Valenciennes.

Acquisition of a Gleeble 3500 system,

Development of a high speed and a high temperature tribometers.

Purchase of the SCALP-04 scattered light polariscop developed by the Laboratory of

Photoelasticity de Tallinn (Estonia) to develop a new platform to measure residual stresses in

tempered glass used in transportation industry.

New analysis procedure combining GTI platform of TEMPO for thermal investigations and

BCRC equipments for physic and chemical investigations on the lubrication in extra-white

glass pressing under industrial forming conditions.

TEMPO/MSM, Materials, Surfaces & Forming

Keywords : rheology, tribology, multiphysic coupling, coatings, glass, forming, tempering.

International collaborations

University of Padova DIMEG, Italy, Pr. S. Bruschi. European Coordinate Action “Virtual Intelligent Forging”

(VIF CA), WP 3, Co-direction of the “friction” benchmark, 1 paper, 1 international conference.

Danmark Tekniske Universitet IPU, Denmark, Dr. M. Arentoft, European Coordinate Action “Virtual Intelligent

Forging”, WP 3, 1 paper, 1 international conference.

Danmark Tekniske Universitet IPU, Denmark, Pr. N. Bay “modelling of Elasto-hydro-plastodynamique

lubrication regime in cold forming”

Faculty of Mechanical Engineering IDMEC, Portugal, Pr. J. César de Sa. Cotutelle PhD, 3 papers, 3 International

Conferences, 1 national conference.

Fraunhofer Institute ITWM for Technical and Industrial Mathematics, Germany, Dr. N. Siedow. 1 European

PhD, 3 papers, 2 international conferences.

Laboratory of Photoelasticity, Estonia, Dr H.Aben. 1 paper, 3 international conferences.

National collaborations CEMEF UMR 7635 (Ecole Nationale Supérieure des Mines de Paris), Pr. J.L. Chenot, Pr Y.Chastel, Pr P.

Montmitonnet, Dr. E. Felder. Co-direction of Qi Zhang post doctoral job (in VIF CA), National project « material

and interfaces in extreme loadings” (thermo mechanical study of tool/chip interfaces in high speed machining

(PGV2)), 1 paper, 1 international conference.

LPMM UMR 7554 (ENSAM de Metz), Pr. A.Molinari. National project “material and interfaces in extreme

loadings” (thermo mechanical study of tool/chip interfaces in high speed machining (PGV2)).

LTN UMR 6607 (Polytech Nantes), Pr. B. Bourouga. National project “material and interfaces in extreme

loadings” (thermo mechanical study of tool/chip interfaces in high speed machining (PGV2)). Collaboration on 2

PhD, 2 papers, 2 international conferences.

LME EA 2447, Pr. F.Monnoyer, co-direction of 3 PhD, 3 papers, 1 international conference.

IEMN/DOAE UMR 8520, Pr. M. Ourak, 3 papers, 2 international conferences.

“Materials and Applications for a Sustainable Use» cluster, writer of Part 4 « Tableware Innovations ».

Administration and Evaluation of Research International

Organization of conferences and symposium: AMPT2010 “Advances in Materials and Processing Technologies”,

novembre, Paris-FR, FSWP2010 “Friction Stir Welding and Processing 2010”, January, Lille-FR, “Wear and Friction

in Metal Forming symposia”of ESAFORM conferences, april 2009 in Twente-NL, april 2011 in Belfast-UK.

Session chairmen ESAFORM 2008, Lyon-FR, ESAFORM 2009, Twente-NL, ICTMP 2010, Nice-FR, AMPT 2010

international conferences,

Co-chairman of Technical Comittee 25: Modelling of Glass Forming of the International Commission on Glass.

Reviewers in “Int. J. of Forming Processes”; “J. of American Ceramic Society”; “J. of Computer and Sciences”; “J.

of Engineering Manufacture”; “J. of Glass Science and Technology”; “J. of Glass Technology”; “J. of The

Institution of Mechanical Engineers Part B and Part E”; “J. of Materials Processing Technology”; “J. of

Mathematics and Computers in Simulation”; “J. of Simulation Modelling, Practice and Theory”; “Surface and

Coating Technology”; “Tribology International”; “Wear”; “Wear Of Material (special issue)”.

National

Organization of conferences: "La face cachée des revêtements", SF2M colloquium, nov. 2008, "Les matériaux au cœur

de l’énergie de demain", SF2M colloquium, nov. 2009, "Fiabilité des structures de transport et de stockage d’énergie",

SF2M colloquium, nov. 2010.

MECHANICS

Awards of the best Master Degree training course, given by SF2M-Section Nord, on “influences of oil lubricants

on the tribological behaviour of stainless steel in cold rolling”, in collaboration with ArcelorMittalStainless.

Campus International pour la Sécurité et l’Intermodalité dans les Transports (CISIT-CPER), Theme manager,

Member of SF2M Section Nord steering committee, organization of SF2M annual colloquium.

Projects

European Coordinate Action VIF CA “Virtual Intelligent Forging”, WP 2, WP3 and WP7.

PRISTIMAT – Interreg IV “development of sol-gel coatings for application to extreme loading tribology”

National project PGV2 “material and interfaces in extreme loadings”, thermo mechanical study of tool/chip

interfaces in high speed machining.

National project SIMULFORGE, improvement of numerical simulation of forging operations.

International Campus of Safety and Intermodality in Transport (CISIT), Task 2: “New challenges for clean, safe

and lightweight vehicles”.

VERACE Project “Analyses of glass behaviour with its environment”.

Funding k€

FP6-FP7 15

Interreg IV 112

CISIT-CPER 736

Industrial project 114

Industrial Contracts Arcelor-Mittal (Isbergues, FR),

Ascometal (Metz, FR),

CETIM-Technical centre of mechanical industry (Saint-Etienne, FR),

Condat Lubrifiants (Lyon, FR),

Corus (Maubeuge, FR),

Daimler AG (Sindelfingen, GE)

Essilor International (Saint-Maur-Des-Fossés, FR),

Forges de Courcelles (Nogent, FR),

Les Verreries du Courval (Sénarpont, FR),

PSA (Mulhouse, FR),

Prelco (Rivière-du-Loup, CA),

Snecma (Colombes, FR),

Sogelub Special Lubricants (Marquain, BE),

Vallourec (Aulnoye-Aymeries, Saint-Saulve, FR).

1 - Presentation

The “Materials, Surface and Forming” (MSM) team was created in 2007 by merging LAMIH’s

“Materials and Surfaces” and “Large strain and Forming” teams. The fusion was managed to

strengthen the research activities of surfaces and interfaces characterization under extreme thermal

and mechanical loadings.

The MSM team is working on two main themes. The first one is related to the characterisation and the

modelling of multiphysic coupling, with applications to glass tempering and metal forming processes.

The main scientific challenges are:

the development of contact, friction and lubricant trapping models,

the understanding of surface and bulk defect occurrences in metal forming and continuous

casting,

the development of coupled computational glass tempering models taking thermal radiation

into account,

the simulation of automotive and optical glass forming.

The second research theme concerns the identification of rheological and tribological behaviour of

coated metal and glass surfaces at high temperature. The main objective is to identify objective data to

characterize surfaces undergoing extreme loadings. Scientific challenges are:

the design of laboratory testing devices able to simulate and measure “true” thermo-

mechanical loadings (“true” means in agreement with industrial ones), with applications to

tribology, metal and glass forming.

the development of innovative methods to identify reliable tribological and rheological data

from test results, with applications to reverse identifications of thermo-mechanical data (such

as contact thermal resistance at glass/mould interface or coefficient of friction) and to predict

surface and bulk defect occurrences.

Application fields of MSM activities range from steel continuous casting, rolling and forging, to glass

forming and tempering. High speed machining, automotive and railway brake systems are also

studied thanks to the development of a high speed friction testing device.

Staff members of MSM are involved in the management of the International Campus of Safety and

Intermodality in Transport (CISIT), Task 2: “New challenges for clean, safe and lightweight vehicles”.

They are also involved in many industrial and academic relationships:

framework agreement with the CETIM (French technical centre of mechanical industry),

resulting from the involvement in many national projects, and leading to collaborations with

French academic partners,

recurrent collaborations with leader companies in the fields of material transformation:

Arcelor-Mittal (member of ArcelorMittal Steelforming network), Corus, Essilor International,

Vallourec,

participation to the VIF Coordinate Action (FP6),

partners in Denmark, Estonia, Germany, Italy and Portugal,

co-direction of a PhD student with the University of Kaiserslautern.

2 - Publications

° Scientific production outside the TEMPO Lab. of new colleagues.

PhD Thesis (5):

Legend: Thesis supervisor, Reviewers, Members of the thesis committee

1. LOUAISIL K. (2008). Laminage à Froid des aciers : analyse des mécanismes de lubrification et de

leurs impacts sur l’usure et le frottement (cold rolling of steels: lubrication mechanisms and their

impact on friction and wear). Univ. Valenciennes et du Hainaut-Cambrésis, december. Thesis

committee: Dubar L., Mazuyer D., Monteil G., Montmitonnet P., Dubar M., Dubois A., Viellard

L., Deltombe R.

2. BELETSERKOVETS A. (2009). Vers une prédiction du profil de rugosité à l’échelle

mésoscopique lors de l’opération de laminage à froid (towards the prediction of surface roughness at a

mesocpopic scale during cold rolling sequences). Univ. Valenciennes et du Hainaut-Cambrésis, July.

Thesis committee: Dubar L., Boyer J.C., Montmitonnet P., Barriere T., Dubar M., Dubois A.,

Deltombe R., Damasse J.M., Vandekinderen H.

3. BROCAIL J. (2009). Analyse expérimentale et numérique du contact à l’interface outil-copeau

lors de l’usinage à grand vitesse des métaux (experimental & numerical analyses of tool/chip interface

during high speed machining of metal). Univ. Valenciennes et du Hainaut-Cambrésis, June. Thesis

committee: Dubar L., Gélin J.-C., Molinari A., Bourouga B., Bricout J.-P., Watremez M., Mocellin

K., Spataro R.

4. DAOUBEN E. (2009). Compréhension des mécanismes d’endommagement en surface des outils

de forge à chaud, effets des lubrifiants (effect of lubricants on damage mechanisms occurring on tool

surface in hot forging). Univ. Valenciennes et du Hainaut-Cambrésis, July. Thesis committee:

Dubar L., Felder E., Picart P., Dubar M., Dubois A., Iordanoff I., P.Y.Bondon P.-Y., Spataro R.

5. HUBERT C. (2010). Influence du cisaillage en continu des tôles d’acier sur l’apparition des

défauts de rives en laminage à froid réversible (influence of edge trimming process on edge

cracking occurrence in steel rolling sequences), Univ. Valenciennes et du Hainaut-Cambrésis,

July. Thesis committee: Dubar L., Montmitonnet P., El Mansori M., Dubar M., Dubois A., Vidal-

Sallé E., Viellard L.

International Papers (18):

1. BELOTSERKOVETS A., DUBOIS A., DUBAR M., DUBAR L., DELTOMBE R.,

VANDEKINDEREN H., DAMASSE J-M. (2008). 2D asperity deformation of stainless steel strip in

cold rolling. International Journal of Material Forming, 1, pp. 351-354, ISSN 1960-6206.

2. BROCAIL J., WATREMEZ M., DUBAR L., BOUROUGA B. (2008). Contact and friction analysis at

tool-chip interface to high-speed machining. International Journal of Material Forming, 1, pp. 1407-

1410, ISSN 1960-6206.

3. DAOUBEN E., DUBOIS A., DUBAR M., DUBAR L., DELTOMBE R., TRUONG DINH N.,

LAZZAROTTO L. (2008). Effects of lubricant and lubrication parameters on friction during hot

steel forging. International Journal of Material Forming, 1, pp. 1223-1226, ISSN 1960-6206.

4. GUILLOT E., BOUROUGA B., GARNIER B., DUBAR L. (2008). Estimation of thermal contact

parameters at a worpiece-tool interface in a HSM process. International Journal of Material Forming,

1, pp. 1031-1034, ISSN 1960-6206.

5. LOCHEGNIES D. (2008). European research teams analyse canadian glass thermal toughening

process. Glass International, 31, n°5, pp. 30-32, ISSN 0143-7836.

6. LOCHEGNIES D. (2008). Numerical cloning of the glass forming process for micron precision

optics. Glass International, 31, pp. 114-116, ISSN 0143-7836.

7. LOUAISIL K., DUBAR M., DELTOMBE R., DUBOIS A., DUBAR L. (2008). Simulation of interface

temperature and control of lubrication in the study of friction and wear in cold rolling.

International Journal of Material Forming, 1, pp. 1239-1242, ISSN 1960-6206.

8. ZHANG Q., ARENTOFT M., BRUSCHI S., DUBAR L., FELDER E. (2008). Measurement of

friction in a cold extrusion operation: Study by numerical simulation of four friction tests.

International Journal of Material Forming, 1, pp. 1267-1270, ISSN 1960-6206.

9. BELOTSERKOVETS A., DELTOMBE R., DUBAR M., DUBAR L., DUBOIS A.,

VANDEKINDEREN H., DAMASSE J-M. (2009). Roughness prediction during cold rolling of

stainless steel strip: fluid structure approach. International Journal of Material Forming, 2, pp. 21-24,

ISSN 1960-6206.

10. HUBERT C., DUBAR M., DUBOIS A., DUBAR L. (2009). 3D modeling of edge trimming process.

International Journal of Material Forming, 2, pp. 837-840, ISSN 1960-6206.

11. LOCHEGNIES D., MONNOYER F. (2009). A 3D computation method for evaluating the impact

of heat transfer on residual stress in thermal tempering of flat glass. Glass Technology - European

Journal of Glass Science and Technology Part A, 50 (6), pp. 297-304, ISSN 1753-3546.

12. LOUAISIL K., DUBAR M., DELTOMBE R., DUBOIS A., DUBAR L. (2009). Analysis of interface

temperature, forward slip and lubricant influence on friction and wear in cold rolling. Wear, 266,

pp. 119-128, ISSN 0043-1648.

13. SZCZUREK E., DUBAR M., DELTOMBE R., DUBOIS A., DUBAR L. (2009). New approach to the

evaluation of the free surface position in roll coating. Journal of Materials Processing Technology,

209, pp. 3187-3197, ISSN 0924-0136.

14. ° BECHET F., LEJEUNE A., POTIER-FERRY M. (2010). Taylor series to solve friction problems.

Comptes Rendus Mécanique, 338, pp. 327-332

15. BOUROUGA B., GUILLOT E., GARNIER B., DUBAR L. (2010). Experimental study of thermal

sliding contact parameters at interface seat of large strains. International Journal Of Material

Forming, 3, pp. 821-824, ISSN 1960-6206.

16. BROCAIL J., WATREMEZ M., DUBAR L. (2010). Identification of a friction model for modelling

of orthogonal cutting. International Journal of Machine Tools & Manufacture, 50, pp. 807-814, ISSN

0890-6955.

17. HUBERT C., DUBAR L., DUBAR M., DUBOIS A. (2010). Experimental simulation of strip edge

cracking in steel rolling sequences. Journal of Materials Processing Technology, 210(12), pp. 1587-

1597, ISSN 0924-0136.

18. LOCHEGNIES D., MOREAU P., HANRIOT F., NAVARUDIGER E., HUGONNEAUX P. (2010).

Experimentation and modelling of thermal replication for the design of 2D1/2 aspherical glass

components. Glass Technology, 51(3), pp. 130-137, ISSN 0017-1050.

19. VIDAL-SALLE E., DUBAR M., BOYER J-C., DUBAR L. (2010). Experimental study of thermal

sliding contact parameters at interface seat of large strains. International Journal Of Material

Forming, 3, pp. 315-318, ISSN 1960-6206.

Conferences with proceedings and scientific committee (10):

1. BELOTSERKOVETS A., DELTOMBE R., DUBAR M., DUBAR L., DUBOIS A., VANDEKINDEREN

H., DAMASSE J-M. (2009). Roughness prediction during cold rolling of stainless steel strip: fluid

structure approach. ESAFORM 2009, P. Boisse, Twente, avril.

2. HUBERT C., DUBAR M., DUBOIS A., DUBAR L. (2009). 3D modeling of edge trimming process.

Esaform, boisse P., Twente, avril.

3. ° BECHET F., BOUDAOUD H., LEJEUNE A., ZAHROUNI H., POTIER-FERRY M. (2010). Toward

the simulation of transportation process. International conference Advances in Materials and

Processing Technologies-AMPT2010, Paris, octobre.

4. ° BECHET F., BOUDAOUD H., LEJEUNE A., ZAHROUNI H., POTIER-FERRY M. (2010).

Numerical modeling of the contact sheet/roller using a coupled AMN/AD method. IV European

Conference on Computational Mechanics, ECCM 2010, Paris, France, mai .

5. BROCAIL J., WATREMEZ M., DUBAR L. (2010). Identification and implementation of new

friction model in the finite element model of orthogonal cutting. International conference advances in

materials and processing technologies, Paris, octobre.

6. DELTOMBE R., BELOTSERKOVETS A., DUBAR M., DUBOIS A., DUBAR L. (2010). Local

approach strategy to the roughness prediction of stainless steel strip. Eric Felder, Pierre

Montmitonnet (Ed.), Tribology of Manufacturing Processes: Proceedings of the 4th International

Conference on Tribology in Manufacturing Processes, 2, Presse des mines, Nice (France), pp. 809-819,

juin, ISBN 978-2-911256-27-1.

7. DELTOMBE R., DUBAR M., DUBOIS A., DUBAR L. (2010). Towards oxide scale behavior

management at high temperature. International conference Advances in Materials and Processing

Technologies-AMPT2010, Paris, octobre.

8. HUBERT C., DUBAR L., DUBOIS A., DUBAR M. (2010). Experimental simulation of strip edge

cracking in steel rolling sequences. International conference Advances in Materials and Processing

Technologies-AMPT2010, Paris, octobre.

9. MERESSE D., SIROUX M., HARMAND S., WATREMEZ M., DUBAR L. (2010). Etude thermique

du contact glissant disque-garniture en situation de freinage automobile. Congrès SFT 2010, Le

Touquet, mai

10. MOREAU P., VIVIER H., BOUTTEVILLE M., LOCHEGNIES D. (2010). Life cycle analysis of the

lubrication in the hollow glass forming process. 10th European Society on Glass Conference,

Deutsche Glastechnische Gesellschaft e.V., Magdeburg (Germany), pp. 44-45, juin.

11. VANDEKINDEREN H., DUBAR L., DELTOMBE R., DAMASSE J-M. (2010). Back-calculation of

friction during cold rolling of stainless steels and its influence on surface quality. Eric Felder,

Pierre Montmitonnet (Ed.), Tribology of Manufacturing Processes: Proceedings of the 4th International

Conference on Tribology in Manufacturing Processes, 2, Presse des mines, Nice (France), pp. 769-779,

juin, ISBN 978-2911256-27-1.

12. VIGNERON L., VIDAL-SALLE E., BOYER J-C., DUBAR M., DUBAR L. (2010). Experimental

validation of the plastic wave approach in hot forging of steels. Eric Felder, Pierre Montmitonnet

(Ed.), Tribology of Manufacturing Processes: Proceedings of the 4th International Conference on Tribology

in Manufacturing Processes, 2, Presse des mines, Nice (France), pp. 385-397, juin, ISBN 978-2-911256-

27-1.

Other Conferences (3):

1. LOCHEGNIES D., MOREAU P. (2008). La modélisation au service de la mise en forme des verres :

2 exemples d'application en soufflage et en affaissement-transfert. Symposium 'Le verre dans tous

ses états'. Réseau de recherches Verrier Lorrain REVELOR, Nancy (France), novembre.

2. LOCHEGNIES D., MOREAU P. (2008). More than 15 years in LAMIH experiment in the

modelling of glass forming. Symposium ' Conditioning of glass melts and forming of glass

products' organized by TC25-TC18 Technical Committees of the International Commission on

Glass, Eindhoven (Pays-Bas), November.

3. DELTOMBE R., DUBAR L., DUBOIS A., DUBAR L. (2010) Vers une maîtrise du comportement à

la déformation des oxydes à haute température. Journée Internationale Francophone de Tribologie,

Albi, mai

Book 1. ° SANCHEZ-PALENCIA E., MILLET O., BECHET F. (Ed.) (2010). Singular problems in shell

theory - computing and asymptotics, lecture notes in applied and computational mechanics.

Springer-Verlag Berlin Heidelberg

Research Reports (6):

1. MOREAU P., LOCHEGNIES D. (2009). Mise au point d'une nouvelle technique de caractérisation

des pâtes SOGELUB pour moules ébaucheurs d'articles de parfumerie en verre extra-blanc.

Rapport intermédiaire de la convention RW C-820095 SOGELUB-INISMa-LAMIH, Université de

Valenciennes et du Hainaut-Cambrésis, Valenciennes, juillet.

2. G. LECLERCQ (2010) Recherche et validation expérimentale de la représentativité du banc

tribologique WHUST pour les produits lubrifiants blancs utilisés en forge a chaud - synthèse des

conditions d’utilisation industrielle des lubrifiants blancs en forge à chaud. Rapport intermédiaire de

la convention N° 34304 CETIM/Valutec/TEMPO, Université de Valenciennes et du Hainaut-

Cambrésis, Valenciennes, septembre.

3. G. LECLERCQ (2010) Recherche et validation expérimentale de la représentativité du banc

tribologique WHUST pour les produits lubrifiants blancs utilisés en forge a chaud - détermination

des conditions de réglage du WHUST pour utilisation de lubrifiants blancs. Rapport intermédiaire

de la convention N° 34304 CETIM/Valutec/TEMPO, Université de Valenciennes et du Hainaut-

Cambrésis, Valenciennes, novembre.

4. MOREAU P., LOCHEGNIES D. (2010). Etude portant sur l'amélioration des performances des

pâtes pour moules ébaucheurs d'articles de parfumerie en verre extra-blanc - Procédure d'essai

sur la plateforme GTI. Rapport intermédiaire de la convention RW C-820095 SOGELUB-INISMa-

LAMIH, Université de Valenciennes et du Hainaut-Cambrésis, Valenciennes, mars.

5. MOREAU P., LOCHEGNIES D. (2010). Etude portant sur l'amélioration des performances des

pâtes pour moules ebaucheurs d'articles de parfumerie en verre extra-blanc - Analyse comparative

des essais avec poinçon Revêtu, poinçon Revêtu Lubrifié et poinçon Lubrifié. Rapport intermédiaire

de la convention RW C820095 SOGELUB-INISMa-LAMIH, Université de Valenciennes et du

Hainaut-Cambrésis, Valenciennes, juillet.

6. MOREAU P., LOCHEGNIES D. (2010). Etude portant sur l'amélioration des performances des

pâtes pour moules ébaucheurs d'articles de parfumerie en verre extra-blanc. Rapport final de la

convention RW C820095 SOGELUB-INISMa-LAMIH, Université de Valenciennes et du Hainaut-

Cambrésis, Valenciennes, novembre.

7. Perspectives

2.1 - Theme 1: multiphysic approaches dedicated to glass and metal forming

processes

2.1.1 Glass Tempering

Team member: D. Lochegnies, J.J. Santin

This pluridisciplinary topic is based on a collaboration initiated in 2000 between the LAMIH UMR

CNSR 8530, the LME EA 2447 in Valenciennes and two European research teams. Upstream research

works concern the development and the weak coupling between CFD (Computational Fluid

Dynamics - LME) models, CM (Computational Mechanics – LAMIH) models and thermal models

(Fraunhofer Institute ITWM for Technical and Industrial Mathematics in Kaiserslautern, Germany).

The objective is to determine the convective and radiative heat transfer and the residual stresses in

glass elements which are heated and suddenly cooled by airjets. The Laboratory of Photoelasticity of

Tallinn collaborates on this topic with its original techniques to measure the stresses in tempered

glass.

The present works concern the analysis of the heat transfers by airjets on curved glass to produce

tempered glass for transportation industry. For that purpose, in the framework of the PhD thesis of M.

Wannassi (begining in October 2009, MNERT grant, Title : “Analysis of the heat transfer by airjets

cooling for the glass tempering”, the jointed research proposed by the MSM and DF2T teams of

TEMPO concerns the analysis and the control of the heat transfer by impacting jets on curved surfaces.

The objective is to go deeper in the understanding of the airjet impact on a curved surface to estimate

with accuracy their contribution on the global heat transfer. It has been emphasized to define original

techniques based on the use of helicoidal jets to improve the convective heat transfer in terms of

performance, homogeneity and control. The scientific bolt to be unlocked is the modelling of the

interaction between the airjets and the surface and the treatment of a transient phenomena linked to a

wide time-scale.

CFD results concerning the airflow under the airjets impinging the glass plate and the heat transfer on the glass surface.

2.1.2 Glass & Metal Forming

Glass forming

Team members: D. Lochegnies, P. Moreau, F. Béchet

In the beginning of the 90s, modelling tools have begun to be used by the research centres of

international glass leaders. At the same period, the glass forming topic was created to develop

efficient simulation models to reproduce with accuracy the multi-physics complex coupling present in

the industrial glass forming processes. By means of different partnerships with industrial glass

companies, leaders in their sector (P.P.G. for automotive glass, Les Verreries du Courval for perfume

bottle, Essilor International for optical glass), this topic is well recognized by the international glass

community (Co-chairman of Technical Committee 25 : Modelling of Glass Forming of the

International Commission on Glass). The research activity concerns the development of non linear

thermo-mechanical models in large deformation and evolutive unilateral contact. Inverse methods are

also used to optimize the glass forming processes with particular applications to the determination of

the tool topology and the temperature map before and during the processing.

The present activities in this topic are related to the glass forming for the future vehicles. An ANR

project - Innovative Materials and Processes has been submitted in February 2009. In a public

transport system which has to be integrated in urban environment, the capacity to propose in the

future attractive design with more freedom concerning shapes and materials might represent a

competitive advantage for the transport industry. To be able to produce new glass shapes for all types

of vehicles in respect of tolerances and optical quality, with mastered costs is a challenge which has to

be raised by the glass industry.

The project relates to the development of methodologies and simulators, as well as forming concept

research to answer future expectations of the designer of the railway transportation. In this context, it

is proposed to design and develop an innovative process for complex laminated glass parts combined

with numerical engineering.

Different scientific bolts have to be opened with appropriate multi-physics approaches in connexion

with mechanical, thermal, automation, sensor fields< Several National and European teams are

implied in this project. The expertise report has noticed that the project is in close relation with the call

of proposal topics; it is linked to an important industrial problematic where stakes, important issues

and multiple scientific bolts are present. The project will be submitted again taking care of the

expertise remarks. The definition of a new consortium with leading transportation and glass

industries is under construction.

Due to the important perspectives of the project, it was possible to begin this research activity on glass

forming for future vehicles by a MNERT grant (PhD of Mr El Cheikh entitled “Mathematical

modelling of multi-layer glass creep forming under radiative heating”) in October 2009. The thesis is

made in collaboration with the EDP (Partial Derivative Equations) team of the LAMAV (Mathematical

Laboratory and Their Applications in Valenciennes EA4015) in Valenciennes and the Transport

Process Department of the Fraunhofer Institute ITWM for Technical and Industrial Mathematics in

Kaiserslautern. For this upstream research, the objective is to develop a new mathematical model to

reproduce the hard coupling between radiative heating and the deformation of glass layers. This

approach is original and is based on the radiative model developed by the Fraunhofer ITWM for semi-

transparent medium, as glass, where radiative phenomena are very complex. For example, the non-

linear system to be solved to obtain the temperature evolution function of time and function of

position in a semi-transparent media like glass is given in one-dimension coordinate system by the

equations below

x

)x(q

x

)x,t(T)T(k

xt

)x,t(T)T(c ggp

where q(x) is the radiative flux given by

0

1

1dd),,x(I)),t,x(T(B)((2

x

)x(q.

As radiation is affected by absorption, emission, scattering out and scattering in, the computation of

q(x) is difficult and time-consuming. New mathematical models have to be developed especially if

solving 2D problems is emphasized and also coupling with mechanical non-linear equations.

Metal forming.

Team members: L. Dubar, M. Dubar, A. Dubois, J.D. Guérin

Transformation and forming processes of metal imply severe conditions of contact in terms of stress,

temperature and/or sliding velocity. The control of these forming processes requires a perfect

knowledge of the tribological and rheological properties of the involved material. It also requires the

use of more and more efficient lubricants, not only to reduce friction, but also to protect tool and

work-piece surfaces.

A first subject studied by the MSM team is related to the identification of bulk behaviour of metal

alloy (mainly steels) at high temperature. Two scientific lines are here developed. The first one deals

with the behaviour and the defectology of metal alloys at high temperature. It is based on

microstructural and textural approaches. The second one is related to the structural behaviour of

metal after in-situ remelting. It is based on a macroscopic approach. Both scientific lines tend to

identify reliable bulk behaviour law by taking into account the effect of local temperature rise on

material structure. They involve direct and inverse identification algorithms, thermo-visco-plastic

models, damage models, function of stress triaxiality and strain levels. Phase transformations that

may occur at given temperatures are considered by the Jonhson-Mehl-Avrami relations. Results

applications range from the identification of bulk behaviour and damage laws to feed finite element

models, to the quantification of bulk defect occurence in continuous casting, or to the characterization

of the heat affected zones in welding.

Example of heating sequence to identify bulk behaviour law after solidification. Effect of cooling rate on fracture surfaces of

M-heat deformed at 1100°C.

Current actions are related to the definition of objective macroscopic criteria of hot ductility and hot

cracking of metal alloys and bimetallic interfaces. Methods are developed to characterize the alloy

according to typical process operating conditions and taking into account the actual thermo-

mechanical history of the material. These methods rely on multi-physics characteristics, divided in

thermal variables (high gradients of heating and cooling, dilatation rate) and mechanical (large strain

rate, to be controlled while characterizing). The next step will be the development of the current

methodologies to study fast austenitization and diffusion phenomena.

The second subject is related to the tribology of metal forming processes. Two major scientific axes are

developed in this subject. The first one concerns the better understanding of tool/lubricant/work piece

interactions during forming. The second one focuses on the characterization of contact and friction

conditions undergoing extreme loading, especially at high temperatures (up to 1200 °C). Both subjects

aim to quantify the influences of phenomena acting at a mesoscopic scale on the whole process

(macroscopic scale). They involve fluid/structure/thermal multi-physics coupling, and macroscopic-

mesoscopic multiscale approaches. They allow to predict extreme surface behaviour and surface

evolutions with time and loadings.

Application fields are numerous: analyses of wear, of adhesion, effect of local strain resulting of the

trapping of lubricant between surface asperities, lubrication defects caused by the growth of oxide

scales at high temperature, prediction of surface damage (scratches, cracks)< Examples of results

obtained these last years are:

the influence of solid particle size on the friction and wear behaviour of hot forging tools

lubricated by graphite in water lubricant. A prototype testing device called WHUST

reproduces industrial hot forging contact conditions. WHUST results are analysed using

microscopic and macroscopic wear markers such as coefficient of friction, sliding length

before scratch, EDS analyses of friction tracks... Tests carried out with different lubricant film

thicknesses and different lubricant particle sizes have shown that the efficiency of the

lubricant film is linked to the structure of the graphite layer more than the lubricant film

thickness.

the prediction of surface roughness after cold rolling of shot blasted stainless steel sheet,

correlated with the gloss of the rolled surface (the gloss being an important quality criteria in

some stainless steel applications). A sequential fluid-structure weak coupling approach was

developed in order to compute the deformation of 2D asperities in mixed lubrication regime.

The cold rolling model involved the strip with its asperities, the lubricant and the working

roll. In order to solve fluid structure interactions, problem was divided in two steps:

o computation using a strong FSI model in the valleys, where hydrostatic effect is

important,

o updating of the volume of each valley to take into account lubricant leakage in the

whole valleys network. Dynamic flow rate (q) was here managed by local Reynolds

equation which included relative speed (Ui1,Ui2,Uroll) and pressure (Pi, Pi-1, Pi+1)

between valleys:

Reynolds equations were solved at the asperity level and lead to the evaluation of the fluid

pressure acting on the asperity sides. Then solid finite element models, where the top of the

asperity was in contact with the working roll and the fluid pressure was applied on asperity

sides, were performed. Reynolds solving and finite element computations were performed on

an asperity, from the entry to the exit of the roll bite. A collaboration with the Danmark

Tekniske Universitet (DTU) is in progress in order to validate these models. The first step of

the collaboration is the achievement of experiments on aluminium strips on which

indentations have been created to represent, one scale upward, the fluid pockets. These tests

are carried out on a specific testing device which involves a glass die. The fluid escape and

entrapment at the asperity level is recorded through the die using a CCD camera. Phenomena

such as Micro Plasto HydroStatic Lubrication (MPHSL) and Micro Plasto HydroDynamic

Lubrication (MPHDL), as well as pockets shrink due to friction and to strip thickness

reduction, are also observed. The second step of the collaboration is the comparison of

experimental results with the sequential fluid-structure weak coupling numerical models.

The next step for the MSM team is to overcome the scientific challenges of high speed tribology. A

new friction stand is in development. Based on a high speed machine engine, it will allow friction

speeds up to 50 m.s-1. Innovative data acquisition channels will be implemented to perform contactless

temperature, speed and acceleration measurements. Collaborations with the DF2T team will be

strengthened to develop thermo-mechanical models of the slider-specimen interface.

2.2 - Theme 2: rheological and tribological behavior of surfaces at high

temperature

2.2.1 Coated metallic Surfaces

Team members: L. Dubar, M. Dubar, A. Dubois, M. Watremez

Coatings represent efficient solutions to protect metal surfaces. They can be hard, used to withstand

important thermo-mechanical loadings (case of PVD or CVD layers to delay wear), or soft, used to

prevent from chemical attacks (case of zinc deposits to protect surfaces from corrosion). Previous

studies have shown that coatings do not only modify the tribological behaviour of the surface, but also

its rheological behaviour, even whith deposit in thin layers. It is therefore essential to characterize the

bulk behaviour in the vicinity of the surface, including the coating and its substrate. A specific reverse

methodology has then been developed to identify coating bulk behaviour. The methodology relies on

innovative homogenisation procedures that do not distinguish the coating from the surface it lies on.

This method offers many advantages:

the thickness of the coating has not to be measured to identify the bulk behaviour law,

it implicitly takes into account the effect of diffusion, or the presence of organo and

intermetallic compounds that may exist at the coating/substrate interface,

the identified bulk behaviour law can be affected to a surface zone thicker than the coating

alone. This peculiarity is very useful for finite element computations. Meshes do not have to

be refined in order to present element size in surface of the same range of the coating

thickness.

Finally, a coupling between bulk behaviour law of coatings, damage and fracture models has been

implemented. The identification methodology has been applied to coated surfaces (PVD and

galvanized coatings) and to mechanically modified surfaces (shot blasted).

The method was used to optimize a skin pass sequence performed on galvanised sheets in order to

reduce zinc fines formation. The skin-pass allows a roughness transfer from the work roll to the

galvanized strip. But during the process zinc particles were teared from the strip and adhered to the

roll. First, tests on galvanized strips were performed and the quantity of zinc fines produced was

measured on the strip and on the tool. Secondly, numerical models were performed with refined mesh

at the vicinity of the contact zone taking into account different surface profiles of the roll. The bulk

behaviour law of zinc coatings was identified and used in the surface of the strip. Material data were

coupled with Lemaitre’s damage criterion in order to predict the wrenching phenomena of the zinc

coating. These predictions were compared to experimental measurements. The correlation was found

to be good and a less polluting roll profile was numerically designed and validated in industry.

Example of the indentation of a zinc coating by roll asperities in the skin-pass of glavanized steel sheet. Comparison between

experimental measurements and numerical simulations, involving Griffith’s fracture model or Lemaitre’s damage model, of

zinc particles tearing from the coatin. (2% of elongation, back tension equal to 0 or 180MPa).

Regarding the tribological performances of surfaces, experimental friction tests have been designed to

simulate thermo-mechanical conditions of contacts close to the industrial ones. Friction tests are

adjustable in terms of contact pressure, plastic strain, sliding velocity, contactors and specimen

temperatures. Contactors and specimens are machined from real tool and work-piece in order to

present the same physical and chemical properties (bulk behaviour, roughness, chemical reactivity<).

Methodologies were developed to identify test parameters adjustments, and to perform reliable and

accurate data processing of the results (identification of coefficient of friction, of damage indicators, of

lubricant efficiency<). Application fields are hot and cold rolling, hot and cold forging, high-speed

machining and braking. Important developments were carried out during the last four years to

improve lubricant application and specimen temperature kinematics. Lubricants can be poured or

sprayed, on the specimen or on the tool surface. The quantity and/or the thickness of lubricants are

controlled. The heating kinetics is optimized to create oxide layers on specimen surface representative

of industrial surfaces. The sensitivities of friction to lubricants, sliding velocities and temperature

variables have been demonstrated. The friction tests and associated methodologies were involved in

the European Coordinate Action “Virtual Intelligent Forging” (VIF CA) Work Package 3, in

partnership with CEMEF (Nice-FR), DIMEG (Padova-I) and IPU (Lyngby-DK).

A new action is starting in the context of the Interrereg IV Pristimat framework, task “new material for

transport applications”. The main subject is the development of “functionally gradient materials” to

increase life of hot forging tools. This work is managed in collaboration with the LCMPA, Laboratory

of CeramicsMaterial Manufacturing, (Maubeuge-FR).

A project related to the prediction of tool life in hot forming will be submitted to the ANR (French

National Research Agency) in March 2011. The project aims to the development of an intelligent

contact element to be implemented in finite element software. The contact element will be linked to a

database to identify the kind of defect that may occur (wear, adhesion, thermal fatigue, etc.), its

severity and its impact on the tool life. The database will be feed with results coming from specific

experimental tests and from industrial case studies. This project will be performed in partnership with

CEMEF (Center for Material Forming, Nice-FR), ICA (Clement Ader Institute, Albi-FR) and the

LaMCoS (Contact and Structural Mechanics Laboratory, Lyon-FR), and five forging industries. It will

involve 3 PhD and one post-doctoral job.

2.2.2 Glass at high temperature: thermal and mechanical behaviours at glass/tool interface

Team members: D. Lochegnies, P. Moreau.

This topic is related to the scientific bolt on the thermal behaviour at glass/tool interface. The GTI

(Glass Tool Interface) platform developed in the Glass Research Centre of LG-Philips in Eindhoven

arrived at the LAMIH in July 2007 is now operational. This platform was purchased due to the end of

research activities in LG-Philips in Eindhoven ; only paper documents were available. Quite two years

were necessary to integrate the equipment in the laboratory, to accumulate experience by self-training,

to solve breaking problems, etc... This platform, unique in the world, reproduces the classical cycle of

glass in the glass forming industry, e.g. the melting, the cutting of the hot glass to create the parison,

the pressing of the parison by instrumented tools with thermocouples and force sensors. This platform

constitutes a real opportunity to pursue investigations on heat transfer at glass/tool interface

developed in the framework of the PhD thesis of S. Gregoire (12/2006-cotutelle with the Faculty of

Mechanical Engineering IDMEC in Porto, Portugal). With GTI, the present activities concern the

analysis of the effect on the lubricant used now in the glass industry on the thermal exchange between

glass and tools during pressing cycles. The first research with GTI is experimental and linked to

lubrication in the case of blank mold used in the perfume bottle industry with extra-white glass. More

than thermal aspects studied during the forming cycles by using GTI, the physical and chemical

aspects of the glass/tool contact are also analyzed with the collaboration of the Glass Division of the

BCRC (Belgium Centre for Ceramic Research) in Mons (Belgium). In the 2008-2009 period which

corresponds to the first year of the research contract with SOGELUB company, investigations have

been realized to determine the GTI forming parameters in order to reproduce with accuracy the

industrial conditions of lubrication and pressing. A specific lubrication system has been designed and

implemented on GTI. Numerous experimentations have been performed to take GTI in hand as

precised above. They have also been used to establish the joint testing procedure to analyze

lubrication using both GTI measurements capabilities and the measurements obtained by the BCRC

equipments.

The first perspective is to focus on the evolution of the thermal, physic and chemical aspects of the

interface behaviour during the cycling pressing of extra-white glass under different lubrication

conditions. Main expected results concern a better knowledge of the life cycle of the lubricant in the

pressing cycle, the impact of lubrication on the tool and on the glass during the pressing. The main

goal is to design a new lubricant improving the present empiricism, common in industry, by these

research investigations.

The second perspective is to study with GTI the sticking conditions at glass/tool interface at high

temperature in presence of lubricant. As for thermal aspects, there is a scientific bolt to be opened on

that matter.