Abstract
A realistic friction model for simple upsetting is developed. The model combines a rigid-plasticity finite element code with a lubrication analysis. The surface roughness effect on lubricant flow is included by using the average Reynolds equation. The active lubrication regime and appropriate friction factor can then be determined from the current local values of interface variables (mean lubricant film thickness, workpiece roughness and tooling roughness) in addition to the more traditional external variables (interface pressure, sliding speed and strain rate). Numerical results for friction stress and normal pressure under different lubrication conditions are compared with previous numerical and experimental investigations.
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