Barrelling of aluminium solid cylinders during cold upsetting with differential frictional conditions at the faces

The friction forces developed between the work-piece and the forming tools are of important consideration in metalworking. In many metalworking processes friction is the predominant factor. This project has been taken up to experimentally study the effect of barreling of aluminium solid cylinders during cold upsetting by introducing different lubricants at one end of the solid cylinder. Experiments were conducted for three aspect ratios. The radius of curvature of bulge measured was found to conform to the calculated one using experimental data. The calculations are made with the assumption that the curvature of the bulge followed the form of a circular arc. A relationship was established between the various bulge parameters like new hoop strain, geometrical shape factor((1)) geometrical shape factor((2)) and stress ratio parameter.