Dynamic friction measurements at sliding velocities representative of high-speed machining processes

Understanding high speed machining processes requires knowledge of the dynamic friction response at the tool-workpiece interface, the high strain rate response of the workpiece material and its fracture mechanisms. In this paper, a novel experimental technique, consisting in the independent application of an axial static load and a dynamic torque, is used to investigate time resolved dynamic friction. Shear stress wave propagation along an input bar, pressing statically against an output bar, is analyzed. The quasi-static and kinetic friction coefficients of Ti-6AI-4V sliding against 1080 Steel, Al 6061-T6 sliding against 1080 Steel, and Al 6061-T6 sliding against Al 7075-T6, with various surface characteristics, are investigated. Sliding velocities up to 6.9 m/s are achieved. Surface roughness is varied to understand its role on the frictional response of the sliding interfaces. The dependence of friction coefficient on material strain-rate sensitivity is also assessed. Measured friction coefficients compared well with values reported in the literature using other experimental techniques. The experimental methodology discussed in this article provides a robust method for direct measurement of the quasi-static and dynamic friction coefficients representative of high-speed machining, metal-forming and ballistic penetration processes.