Materials

& Design
Materials and Design 27 (2006) 147–155
www.elsevier.com/locate/matdes

Technical report

Effect of friction on barrelling in square billets

of aluminium during cold upset forging
a,*
K. Manisekar , R. Narayanasamy b, S. Malayappan a

a
Department of Mechanical Engineering, National Engineering College, Kovilpatti 628 503, Tamil Nadu, India
b
Department of Production Engineering, National Institute of Technology, Tiruchirapalli 620 015, Tamil Nadu, India

Received 19 May 2004; accepted 27 September 2004

Available online 5 November 2004

Abstract

This work deals with the generation of data on cold upset forging of square billets of annealed aluminium under different fric-
tional conditions. Three different aspect ratios and constant load levels were considered for the above said upsetting experiment. The
calculations were made on the assumption that the curvature of the barrel followed the geometry of circular arc. The measured
radius of curvature of the bulge was found to confirm with calculated values obtained using experimental data. Relationships were
established between the experimentally derived values of friction factors for different lubricants from standard compression tests and
bulge parameters such as new hoop strain, geometrical shape factor and the stress ratio parameter and hydrostatic stress.
Ó 2004 Elsevier Ltd. All rights reserved.

1. Introduction
One of the most widely employed forging processes is
that of the axial cold upsetting of cylinders. A series of
investigations have been going on in bulk metal form-
ing. Friction plays an important role in all metal work-
ing processes. The role of friction in bulk metal forming
has been carried by many researchers [1–5]. Syed Abu
Thahear et al. [6,7] studied the effect of barrelling in sol-
ids of truncated cone billets. Most of the researchers
adopted the ring compression test as the tool for quan-
titative measurement of friction [8–11]. Male and De-
pierre [12] investigated the validity of mathematical
solution of the ring compression test.
In upsetting, the existence of frictional constraints be-
tween the dies and the work piece directly affect the plas-
tic deformation of the later. When a solid specimen
(cylindrical or square billets) is compressed axially be-
* Malayappan and Narayanasamy [17] studied the ef-
Corrresponding author. Tel.: +91 4632 222502.
E-mail addresses: kmsekar1@rediffmail.com (K. Manisekar), nar-
ayan@nitt.edu (R. Narayanasamy).
tween the punch and the bottom platen, the work piece
material in contact with their surfaces undergoes heter-
ogeneous deformation resulting in ‘‘barrelling’’ of the
specimen.
The friction at the faces of contact retards the plastic
flow of metals and the surfaces and in its vicinity. A con-
ical wedge of a relatively undeformed metal is formed
immediately below it while the rest of the cylinder metal
suffers high strain hardening and bulges out. However,
in practice, the use of lubricants reduces the degree of
bulging. Hence, it is necessary to apply a correction fac-
tor for bulging during design of die. Kulkarni and
Kallpakjin [13] studied the arc of barrel as circular or
parabolic where as Schey et al. [14] presented a compre-
hensive report on the geometrical factors that affect the
shape of the barrel. Banerjee [15] and Narayanasamy
et al. [16] showed theoretically that the barrel radius
could be expressed as a function of height strain and
confirmed the same through experimental evidences.
fect of barrelling in aluminium solid cylinders with
constrained at one end. So far, the attempt had been

0261-3069/$ - see front matter Ó 2004 Elsevier Ltd. All rights reserved.
doi:10.1016/j.matdes.2004.09.019
148 K. Manisekar et al. / Materials and Design 27 (2006) 147–155
made to relate the friction factor found out from the
ring compression test with the bulge parameters ob-
tained during cold upsetting of cylindrical specimens
[18].
The present investigation is aimed to establish a rela-
tionship between the friction factor which is derived
from standard compression test with bulge parameters
such as the new hoop strain, the hydrostatic stress, the
new geometrical shape factor and the stress ratio param-
eter arrived based on contact width, initial height and
height dimensions obtained during the deformation of
square billets.
2. Experimental details
2.1. Ring compression test
Specimens of 24 mm outer diameter, 12 mm inner
diameter and 8 mm height (corresponding to standard
ratio OD:ID:h = 6:3:2) were prepared from annealed
bar of commercially pure aluminium. The standard
ratio 6:3:2 was selected because earlier investigations
using ring compression tests had concluded that the
satisfactory results were obtained only with this ratio.
The initial outer diameter ODi, initial inner diameter
IDi, and the initial height ho were measured. After
each incremental loading the bulged outer diameter
ODf, bulged inner diameter IDf, and reduced speci-
men height hf were measured for various lubricants
and also with no lubrication. The loads used for each
deformation were recorded from the dial indicator of
the compression testing machine and the dimensions
were measured using a digital vernier caliper. The
friction factors were determined as explained else-
where [18] by the above experiment are given in Ta-
ble 1.
2.2. Cold upsetting test
Square specimens of 19 mm side length with varying
heights corresponding to the aspect ratios of 0.75,1.00
Table 1
Values of ÔmÕ obtained from ring compression tests
Sl. No. Lubricant Friction factor m
1 Molybdenum disulphide 0.47
2 Zinc stearate 0.61
3 White grease 0.66
4 SAE 40 oil 0.72
5 Dry lubrication 0.76
6 Graphite 0.55
7 Zinc stearate + white grease 0.57
8 Molybdenum disulphide + SAE 40 oil 0.59
9 Graphite + SAE 40 oil 0.69
and 1.25 were prepared from the annealed bar of com-
mercially pure aluminium. The upset forging tests were
conducted at room temperature with different lubri-
cants, namely grease, zinc stearate, molybdenum disul-
phide, SAE 40 oil, graphite, graphite + SAE 40 oil,
zinc stearate + white grease, molybdenum disul-
phide + SAE 40 oil and dry lubrication using the flat
dies. The axial upsetting tests were carried out using
compression testing machine of 200 ton capacity. For
each test, nine specimens of the same dimensions were
taken and deformed to same strain levels. After each
test, the following parameters were measured as shown
in Fig. 1(a):
1. Height of the deformed specimen (hf).
2. Circumferential contact length of the specimen (lc1,
lc2, lc3 and lc4).
3. Circumferential bulged length (lb1, lb2, lb3 and lb4).
4. Contact width of the specimen (lcw).
5. Bulged width of the specimen (lbw).
6. The radius of the barrel (R).
7. Contact area (Ac).
The load used during each deformation was recorded
from the dial indicator of the universal testing machine.
Extreme care was taken to place the axis of the cylin-
drical specimen concentric with the axis of the ram.
The barrel radius and circumferential lengths were
traced using a profile projector and these values were
measured using tablets (digitizers) in Auto CAD soft-
ware and the rest of the dimensions were measured using
digital micrometer.
3. Results and discussion
Fig. 1(b) shows the relationship between the axial
strain ez = ln(ho/hf) and the hoop strain eh = ln(lc/a). This
plot is straight line with almost same slope, irrespective
of aspect ratios tested.
Fig. 2 shows the plot drawn between the axial strain
ez = ln(ho/hf) and the new hoop strain, e00h for different as-
pect ratios. This plot is a straight line with different slope
values. The new hoop strain ðe00h Þ is calculated based on
the following expression:
e00h ¼ lnðð2l2b þ lc2 Þ=3a2 Þ; ð1Þ
where lb is the bulged length (circumferential length/4) in
mm, lc is contact length (circumferential length/4) in
mm, and a is the side of the square in mm unit.
Fig. 3 is drawn between the measured radius of cur-
vature of the barrel and the calculated radius of curva-
ture. It is observed that the calculated values of the
radius of curvature are in close proximity with measured
values. Hence, the assumption that the barrel radius
obeys circular arc is true.
 K. Manisekar et al. / Materials and Design 27 (2006) 147–155 149

Fig. 1. (a) Barrelling under ideal condition. (b) Relationship between hoop strain and axial strain.

Fig. 4 is the plot drawn between the friction fac-
tor and the natural logarithmic value of the meas-
ured values of radius of curvature for different
constant load values. Irrespective of aspect ratios
and strain levels, the rate of change of the friction
factor with respect to the logarithmic value of meas-
ured radius is not same for different strain levels and
slopes are reported in the same Figure. The friction
factor is decreasing with the increasing value of
ln(Rm).
150 K. Manisekar et al. / Materials and Design 27 (2006) 147–155

Fig. 2. Relationship between axial strain and new hoop strain.

Fig. 5 shows the relationship between the friction
factor ÔmÕ and the new geometrical shape factor
(GSF) for three different loads. The plot is a
straight line relationship with different slope values
and the friction factor decreases with the increasing
value of the new GSF. The rate of change of the
friction factor ÔmÕ with respect to the new geometri-
cal shape factor is not same for different strain
levels.
Fig. 6 is a plot drawn between the friction factor ÔmÕ
and the natural logarithmic value of stress ratio param-
eter which shows a straight line relationship. As the
ln(stress ratio parameter) increase, the friction factor
ÔmÕ value decreases. The rate of change of the friction
factor ÔmÕ with respect to the natural logarithmic value
of stress ratio parameter is not same for different strain
levels.
4. Conclusions
The major findings that can be drawn from the pre-
sent investigations are as follows:
1. It is observed that molybdenum disulphide exhibits
efficient lubricating property with a friction factor
of 0.47, comparing with other lubricants tested.
2. The relationship between the calculated and the
measured radius of curvature of the barrel con-
formed to a straight-line behaviour. The calculated
 K. Manisekar et al. / Materials and Design 27 (2006) 147–155 151

Fig. 3. Relationship between measured radius and calculated radius.

values of radius of curvature are in close agreement
with the measured values. It is further found that
the radius of curvature of the bulge fits a circular
arc.
3. The bulge radius increases with the increasing friction
factor. Hence, the bulging produced is the lowest for
molybdenum disulphide irrespective of the aspect
ratios tested.
4. The relationship between the bulge radius and the
new geometrical shape factor is a straight line. This
suggests that a power law relationship exists between
the friction factor and the new geometrical shape fac-
tor which is expressed as follows:
m ¼ C 1 ln S þ C 2 ;
where ÔmÕ is the friction factor, ÔSÕ is geometrical
shape factor, and ÔC1Õ and ÔC2Õ are the experimentally
determined constants.
5. The radius of curvature of bulge decreases linearly
with increasing value of ln(the stress ratio parameter).
The logarithmic plot shows that the straight relation-
ship between friction factor and the logarithmic value
of stress ratio parameter is the manifestation of the
following expression:
m ¼ C 3 ln½ðrm =rÞðho
hf Þ þ C 4 ;
where m is the friction factor, S is geometrical shape
factor, rm is hydrostatic stress, r is representative
stress, ho is initial height of the cylinder, hf is final
152 K. Manisekar et al. / Materials and Design 27 (2006) 147–155

Fig. 4. Relationship between friction factor and ln(measured radius).

height of the cylinder after deformation and C3 and rh ¼ ½ð1 þ 2aÞ=ð2 þ aÞrz ; ðA:2Þ
C4 are experimentally determined constants.
and the representative stress can be expressed as
6. Friction factor values for combinations of lubricants
lie between friction values for the respective two par-  ¼ ½1=ð2 þ aÞ½3ð1 þ a þ a2 Þ0:5 rz :
r ðA:3Þ
ent lubricants.
The hydrostatic stress is given as follows:
rm ¼ ð1=3Þðrh
rz Þ: ðA:4Þ

Appendix A

As explained elsewhere [19], the representative strain Appendix B. Barrelling in solid square billets
ðeÞ can be calculated as follows
p As explained elsewhere [20], the expression of bulging
e ¼ ð2= 3Þð1 þ a þ a2 Þ0:5 ez ; ðA:1Þ
can be written as follows under the condition that this
where a is the slope between hoop strain (eh) and the ax- follows circular arc barrelling effect:
ial strain (ez). Since the radial stress (rr) is zero at the
free surface, it follows the flow rule that ðp=12Þð2l2b þ l2c Þhf ¼ ðp=4Þða2 ho Þ: ðB:1Þ
 K. Manisekar et al. / Materials and Design 27 (2006) 147–155 153

Fig. 5. Relationship between geomentrical shape factor and friction factor.

(under volume constancy principle), where lb is the ez ¼ lnðho =hf Þ;

bulged length (bulged circumference/4), lc is contact e00h ¼ lnðð2l2b þ l2c Þ=3a2 Þ:
length (contact length along the circumference/4), hf
is height of the billet after deformation, a is side length From [4], the expression for the radius of curvature of
of square, and ho is the initial height of the square barrel is as follows:
billet.
Eq. (B.1) can be written as follows: x ¼ R
ðR2
h2f =4Þ ;
0:5
ðB:4Þ
ðho Þ=ðhf Þ ¼ ð2l2b þ l2c Þ=3a2 : ðB:2Þ
where x = (lbw
lcw)/2, R is the radius of the curvature
Taking natural logarithm on both sides, the equation of the barrel, lbw is the bulged width, and lcw is the con-
becomes tact width.
Simplifying the expression (B.4), the expression for
ez ¼ e00h ; ðB:3Þ
the barrel radius R can be obtained neglecting x2 term
where (because the quantity of the x is very less).
154 K. Manisekar et al. / Materials and Design 27 (2006) 147–155

Fig. 6. Relationship between friction factor and ln(stress ratio parameter).

Therefore [2] Yang DY, Choi Y, Kim JH. Analysis of upset forging of
cylindrical billets considering the dissimilar frictional conditions
R¼ h2f =8x: ðB:5Þ at two flat die surfaces. Int J Machine Tools Manuf 1991;31:
Otherwise 397–404.
[3] Chen FK, Chen CJ. On the non-uniform deformation of the
R ¼ h2f =4ðlbw
lcw Þ: ðB:6Þ cylinder compression test. J Eng Mater Technol 2000;122:192–7.
[4] Narayanasamy R, Pandey KS. Phenomenon of barrelling in Al
Multiplying ho on both sides by the expression (B.6), the solid cylinders during cold upset-forging. J Mater Proc Technol
following expression can be obtained: 1997;70:17–27.
h i
[5] Bay N. Friction stress and normal stress in bulk metal forming
R0:50 ¼ ðhf =ho Þho = 2ðlbw
lcw Þ0:5 : ðB:7Þ processes. J Mech Work Technol 1987;14(issue 2):203–23.
[6] Syed Abu Thaheer A, Narayanasamy R, Ganesh Babu K. Some
From the expressions (B.2) and (B.7), the barrel radius
aspects of barrelling in unlubricated copper solids of truncated
becomes as follows: cone billets during cold upset forging. Met Mater Process
ho 3a2 2002;14(4):295–304.
R0:50 ¼ 2 2
: ðB:8Þ [7] Syed Abu Thaheer A, Narayanasamy R, Pandey KS. Barrelling in
2ðlbw
lcw Þ1=2 ð2lb þ lc Þ truncated unlubricated aluminium cone billets during cold upset
forging. Trans Indian Inst Met 2003;56(6):591–7.
[8] Hwu Y-J, Hsu C-T, Wang F. Measurement of Friction and Flow
stress of steel at room and elevated temperature by ring
References compression test. J Mater Process Technol 1993;37:315–9.
[9] Bugini A, Maccarni G, Giardini C, et al.. The elevation of flow
[1] Abdul NA. Friction determination during plastic deformation of stresses and friction in upsetting of rings and cylinders. Ann CIRP
metals. Ann CIRP 1981;30:143–6. 1993;42:335–8.
 K. Manisekar et al. / Materials and Design 27 (2006) 147–155
[10] Oh KH, Mun JH. An analysis of ring upsetting sintered material.
J Mech Work Technol 1984;9:279–91.
[11] Danckert J. Analysis of the ring test method for the evaluation of
frictional stresses in bulk metal forming processes. Ann CIRP
1988;37:217–20.
[12] Male AT, Depierre V. The Validity of mathematical solutions
determining friction from ring compression test. Trans ASME J
Lubr Technol 1970;92:389–97.
[13] Kulkarni KM, Kalpakjian S. A study of barrelling as an example
of free deformation. ASME J Eng Ind 1969;91:743–54.
[14] Schey JA, Venner TR, Takomana SL. Shape changes in the
upsetting of slender cylinders. ASME J Eng Ind 1982;104:
79–83.
[15] Banerjee JK. Barrelling of solid cylinders under axial compres-
sion. ASME J Eng Mater Technol 1985;107:138–44.
155
[16] Narayanasamy R, Murthy RSN, Viswanatham K, Chary GR.
Prediction of the barrelling of solid cylinders under axial
compressive load. J Mech Work Technol 1988;16:21–30.
[17] Malayappan S, Narayanasamy R. Barrelling of aluminium solid
cylinders during cold upset forging with constrained at one end.
Int J Mater Sci Technol 2003;19:507–11.
[18] Malayappan S, Narayanasamy R. Some observation on bar-
relling of aluminium solid cylinders during cold upsetting using
different lubricants. Int J Mater Sci Technol 2003;19:1705–8.
[19] Sowerby R, OÕReilly I, Chandrasekaran N, Dung NL. Materials
testing for cold forging. ASME J Eng Mater Technol
1984;106:101–6.
[20] Manisekar K, Narayanasamy R. Phenomenon of barrelling in
square billets of aluminium during cold upset forging. Int J Adv
Manuf Technol 2003;21:84–90.