FEM simulation of a friction testing method based on combined forward conical can-backward straight can extrusion

A new friction testing method based on combined forward conical can-backward straight can extrusion is proposed in order to evaluate friction characteristics in severe metal forming operations. By this method the friction coefficient along the conical punch surface is determined knowing the friction coefficient along the die wall. The latter is determined by a combined forward and backward can extrusion of straight cans. Calibration curves determining the relationship between punch travel, can heights, and friction coefficient for the two rests are calculated based on a rigid-plastic FEM analysis. Experimental friction tests are carried out in a mechanical press with aluminium alloy A6061 as the workpiece material and different kinds of lubricants. They confirm that the theoretical analysis results irt reasonable values for the friction coefficient.