A new method for investigating friction effects in forging processes using open die compression test of a cylindrical rod

The friction factor between workpiece and die is one of the important factors that affects the design steps of a forging process. By now, various methods, that each one has its own advantages and disadvantages, have been used by other researchers in order to estimate the friction factor. In this paper, a new method ,which has been named open die compression of a cylindrical rod, has been presented to estimate the friction factor and investigated numerically and experimentally. As Titanium alloys are classified as a kind of hard to work metal alloys and it is important to investigate friction in forming processes of titanium, a sample of Ti-6Al-4V bar has been investigated in experimental test. The results show that this method has an agreeably high sensitivity to friction factor value; So that calibration graphs are separate enough. Also, the geometrical shape of the workpiece causes a great surface expansion during the test.