Skip to main content
Log in

Evaluation of friction in upsetting

  • Production Process
  • Published:
Production Engineering Aims and scope Submit manuscript

Abstract

Distributions of contact stresses at the neutral point in metal forming are very hard to be properly predicted due to the complex interface situation and lack of suitable friction models. In this paper, the dynamic friction model in which the friction depends on both time rate of strain and normal pressure has been applied to predict contact stresses in cylinder upsetting. Case studies have shown that the predicted results agreed with the experimental data chosen from literature. By comparing with two other friction models, the dynamic friction model seemed to give a better solution.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Fig. 1
Fig. 2
Fig. 3

Similar content being viewed by others

References

  1. Von Karman TH (1925) On the theory of rolling. Zeitschrift für angewandte Mathematik und Mechanik 5:139–141

    MATH  Google Scholar 

  2. Kudo H (1960–61) Some analytical and experimental studies of axi-symmetric cold forging and extrusion. International Journal of Mechanical Science, Part I: 2:102–27; Part II: 3:91–117

    Google Scholar 

  3. Schey JA (1983) Tribology in metalworking: friction, lubrication and wear. American Society For Metals, Metals Park, USA

    Google Scholar 

  4. Wanheim T (1973) Friction at high normal pressures. Wear 25:225–244

    Article  Google Scholar 

  5. Wanheim T, Bay N, Petersen AS (1974) A theoretically determined model for friction in metal working processes. Wear 28:251–258

    Article  Google Scholar 

  6. Wanheim T, Bay N (1978) A model for friction in metal forming processes. Ann CIRP 27(1):189–194

    Google Scholar 

  7. Bay N (1987) Friction stress and normal stress in bulk metal—forming processes. J Mech Work Technol 14:203–223

    Article  Google Scholar 

  8. Orowan E (1946) Section V: a simple method of calculating roll pressure and power consumption in hot flat rolling. Iron Steel Institute. Spec Rep 34:124–146

    Google Scholar 

  9. Alexander JM (1955) A slip line field for the hot rolling process. Proc Inst Mech Eng 169:1021–1030

    Article  Google Scholar 

  10. Tan X, Martins PAF, Bay N, Zhang W (1998) Friction studies at different normal pressures with alternative ring-compression tests. J Mater Process Technol 80–81:292–297

    Article  Google Scholar 

  11. Levanov AN (1997) Improvement of metal forming processes by means of useful effects of plastic friction. J Mater Process Technol 72:314–316

    Article  Google Scholar 

  12. Chen CC, Kobayashi S (1978) Rigid plastic finite element analysis of ring compression. In: Armen H, Jones RF Jr (eds) Applications of numerical methods to forming processes. AMD, vol 28. American Society of Mechanical Engineers, New York, pp 163–174

    Google Scholar 

  13. Bay N, Eriksen M, Tan X, Wibom O (2002) An empirical model for friction in cold forging. keynote paper, Euromech 435 Colloquium, FWMF (Friction and Wear in Metal Forming), June 2002, Valenciennes, France

  14. Tan X, Bay N, Zhang W (1999) A new friction test using simple upsetting and flow analysis. In: Geiger M (ed) Advanced technology of plasticity 1999, proceedings of 6th international conference of technology of plasticity (ICTP), vol 1. Nuremberg, Springer. pp 365–370

  15. Wilson WRD (1974) An isoviscous model for the hydrodynamic lubrication of plane strain forging processes with flat dies. Trans ASME J Lub Technol 96:539–546

    Article  Google Scholar 

  16. Wilson WRD, Wong CJ (1974) Analysis of lubrication film formation processes in plane strain forging. Trans ASME J Lub Technol 95:605–610

    Article  Google Scholar 

  17. Wilson WRD, Wang JJ (1984) Hydrodynamic lubrication in simple stretch forming processes. Trans ASME J Tribol 106:70–77

    Article  Google Scholar 

  18. Wilson WRD, Huang XB, Hsu TC (1995) A realistic friction model for computer simulation of sheet metal forming processes. J Eng Ind 117:202–209

    Article  Google Scholar 

  19. Wang JP (2002) An investigation into friction in dynamic plane upsetting. J Mater Process Technol 123:323–328

    Article  Google Scholar 

  20. Ettouney OM, Stelson KA (1990) An approximate model to calculate fold over and strains during cold upsetting of cylinders; part I: formulation and evaluation of the fold over model; Part II: use of the fold over model to estimate friction. Trans ASME J Eng Ind 112(260–266):267–271

    Article  Google Scholar 

  21. Schey JA, Venner TR, Takomana SL (1982) Shape changes in the upsetting of slender cylinders. Trans ASME J Eng Ind 104:79–83

    Article  Google Scholar 

  22. Wallace PW, Schey JA (1967) Speed effects in forging lubrication. Trans ASME J Lubric Technol 93:317–323

    Article  Google Scholar 

  23. Kulkarni KM, Kalpakjian S (1969) A study of barrelling as an example of free deformation in plastic working. Trans ASME J Eng Ind 91:743–754

    Google Scholar 

  24. Tan X (2001) Friction-reducing contact area expansion in upsetting. J Eng Tribol Proc Inst Mech Eng Part J 215:189–200

    Article  Google Scholar 

  25. Unksov EP (1961) An engineering theory of plasticity. Butterworths, London

    Google Scholar 

  26. Yoneyama T (1990) Direct measurement of stress and heat between workpiece and tool in metal forming. Ann CIRP 39(1):219–222

    Article  MathSciNet  Google Scholar 

  27. Lenard JG (1992) Friction and forward slip in cold strip rolling. Tribol Trans 35(3):423–428

    Article  Google Scholar 

  28. Guobrial MI (1989) A photo elastic investigation on the contact stresses developed in rolls during asymmetrical flat rolling. Int J Mech Sci 31(10):751–764

    Article  Google Scholar 

  29. Tan X (2007) Friction of plasticity: application of the dynamic friction model. J Eng Tribol Proc Inst Mech Eng Part J 221:115–131

    Article  Google Scholar 

  30. Tan X, Yan X, Juster NP, Raghunathan S, Wang J (2008) Dynamic friction model and its application in flat rolling. J Mater Process Technol 207:222–234

    Article  Google Scholar 

  31. Bay N, Gerved G (1984) Friction and pressure distribution in disk forging. Presented at 17th international cold forging group plenary meeting, Nagoya, Japan, Sep 1984

  32. Pearsall GW, Backofen WA (1963) Frictional boundary conditions in plastic compression. J Eng Ind ASME 85:68–76

    Google Scholar 

  33. Baillet L, Boyer JC (1995) Experimental results of the friction stress distribution for the upsetting of cylinders. In: Shen SF, Dawson PR (eds) Simulation of materials processing: theory, methods and application, proceedings of the 5th international conference on numerical methods in industrial forming processes—NUMIFORM’95. A.A. Balkema, Rotterdam. pp 209–214

  34. Danckert J (1977) Modelmaterialeteknik (Model material technique). Ph.D. thesis, Department of Mechanical Processing of Materials, Technical University of Denmark. MM77.23 (in Danish)

  35. Kojima Y, Mizuno T (1989) A measurement of contact-pressure distributions in the upsetting of cylindrical billets. JSME Int J Ser I 32(4):567–571

    Google Scholar 

  36. Hu XL, Hai JT, Chen WM (2004) Experimental study and numerical simulation of the pressure distribution on the die surface during upsetting. J Mater Process Technol 151:367–371

    Article  Google Scholar 

  37. Plancak M, Bramley AN, Osman FH (1996) Some observations on contact stress measurement by pin load cell in bulk metal forming. J Mater Process Technol 60:339–342

    Article  Google Scholar 

  38. Tselikov AI (1958) Present state of theory of metal pressure upon rolls in longitudinal rolling. STAL 18(5):434–441

    Google Scholar 

  39. The MSC Institute of Technology (2000) MSC. Marc advanced course. MSC. Software Corporation, Los Angeles

    Google Scholar 

  40. Petersen SB, Martins PAF, Bay N (1997) Friction in bulk metal forming: a general friction model vs. the law of constant friction. J Mater Process Technol 66:186–194

    Article  Google Scholar 

  41. Tan X, Bay N, Zhang W (2003) Friction measurement and modelling in forward rod extrusion test. J Eng Tribol Proc Inst Mech Eng Part J 217(1):71–82

    Article  Google Scholar 

  42. Tan X (1999) Friction modelling in connection with cold forming processes. Ph.D. thesis, Department of Manufacturing Engineering, Technical University of Denmark, Denmark, IPT.024.00 (MM00.15)

  43. Tan X, Conway PP, Sarvar F (2005) Thermo-mechanical properties and regression models of alloys: AISI 305, CK 60, CuBe2 and Laiton MS 63. J Mater Process Technol 168:152–163

    Google Scholar 

  44. Lange K (1985) Handbook of metal forming. McGraw-Hill Book Company, New York, USA

    Google Scholar 

  45. Hosford WF, Caddell RM (1993) Metal forming: mechanics and metallurgy, 2nd edn. PTR Prentice Hall, Upper Saddle River, NJ

    Google Scholar 

Download references

Author information

Authors and Affiliations

Authors

Corresponding author

Correspondence to Xincai Tan.

Rights and permissions

Reprints and permissions

About this article

Cite this article

Tan, X. Evaluation of friction in upsetting. Prod. Eng. Res. Devel. 5, 141–149 (2011). https://doi.org/10.1007/s11740-010-0287-5

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s11740-010-0287-5

Keywords

Navigation