Abstract
A method of assessing die-workpiece interface friction that is related to the amount of workpiece deformation in the upsetting process is presented in this paper. The method is used in conjunction with a thermo-elastic-plastic model in which the flow stress is taken as a function of strain, strain rate and temperature. During the upsetting process, the die-workpiece interface friction is not constant, a continuously varied situation existing that is regarded as a function of the amount of workpiece deformation. Functions (an exponential function and a polynomial function) in terms of height reductions of workpiece are utilized to simulate this continuously-varying phenomenon. The barreling of the free surface of the workpiece, which is taken from experiment, is used to modify the coefficients of the proposed functions in succession. The forging load obtained is consistent with the results of experiment from which it is inferred that the interface-friction method that has been developed can deal with the problem of the upsetting process quite satisfactorily.
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