Surface roughness evolution in FEA simulations of bulk metal forming process

► Workpiece surface topography plays a major role in metal forming processes. ► Process feasibility depends directly upon lubricant transport of workpiece surface. ► Surface roughness evolution can be simulated in bulk forming process by using FEA. ► Surface evolution model is tested successfully in extrusion process. ► Simulated surface roughness can be used for new friction and wear models in future. Workpiece surface topography plays a major role in metal forming processes due to impact on tribology. Especially process feasibility depends directly upon the ability of the tribological system to separate tool and workpiece during the process and realize good lubrication to minimize wear due to shear friction stresses. This paper presents a new approach to describe the surface evolution of workpiece surfaces during cold forging operations. Results can be used to gain knowledge on tribological loads in forming processes and to formulate better friction models since the description takes into account the evolution of the contact area of the contact partners.