Friction:

Friction

is the force resisting the relative motion of solid surfaces, fluid layers, and material elements sliding against each other. In general it has negative impact on process parameters, die-life as well as work piece quality. -it should be reduced always improve the performance

Types of friction:
1.

2. 3. 4.

5.

Dry friction resists relative lateral motion of two solid surfaces in contact. Dry friction is subdivided into static friction ("stiction") between non-moving surfaces, and kinetic friction between moving surfaces. Fluid friction describes the friction between layers within a viscous fluid that are moving relative to each other. Lubricated friction is a case of fluid friction where a fluid separates two solid surfaces. Skin friction is a component of drag, the force resisting the motion of a solid body through a fluid. Internal friction is the force resisting motion between the elements making up a solid material while it undergoes deformation.

Reduce friction :
-Can we quantify friction range ?.. Frictional shear stress is given by

where
is coefficient of friction and its value ranges from 0 to 0.577

p is contact pressure.
f is a frictional shear stress. m is a friction ratio 0<m< 1

Contd..
By limiting the non-dimensional parameters such as * friction factor m * coefficient of friction . The friction can be controlled.

For determining the non dimensional parameters

different experiment models have been developed. All of them simulate the real metal forming techniques such as sheet metal forming, extrusion, hot forging, cold forging etc.

Experimental techniques:
The various experimental models for the measurement of friction in bulk metal forming are as follows. Ring-compression test Forward bar extrusion Backward cup extrusion Combined forward backward extrusion Backward extrusion with twist Backward forward hollow test

Contd..
T-shape compression Open die backward extrusion Tapered plug penetration Conical tube-upsetting test

-these are the different types of test for evaluating the friction. most commonly used technique ring compression test.

Ring-compression test:
Most commonly used technique to evaluate the friction condition in metal forming technique. Principle :

For the given conditions of temperature , strain, strain rate and initial specimen geometry of ID::OD::H,the deformation of internal diameter of the ring may be calculated as a unique function of interfacial friction coefficient.

Contd..
When the specimen is plastically compressed between the two flat surfaces the internal diameter of the specimen will be increased or decreased. Increase-if interface friction is low. Decrease if interface friction is high. By measuring the change in internal diameter. It is possible to evaluate friction condition ,through the use of friction calibration curve.

Testing machine:

Shear factor range:

Calibration curve :

Compression twist type :

Backward extrusion type test :

Conclusion :
For analytical analysis and process simulation knowledge of friction magnitude is essential. Ring test-low contact press and low strainalternative methods are there for higher deformation. Thank you