Investigations on the influence of the shape factor and friction in compression processes of cylindrical billets of AA 6082-T6 aluminum alloy by numerical and experimental techniques

The material characterization under similar load conditions to those applied during manufacturing is important in order to analyse Bulk Forming Compression Processes from a more realistic point of view. Open die forging of AA 6082-T6 aluminum alloy has been analysed by using experimental techniques and Finite Elements Method (FEM). The influence of the workpiece geometry on the effects that friction produces in typical process variables such as applied forces, contact pressures and stresses and strains in work pieces has been analysed by FEM simulation. It has been shown that higher shape factors of the initial work piece geometry are recommended in such a way that friction effect is minimised. These results are interesting in order to decrease the required energy of the process and the tool wear, and could be used in further analysis of stamping processes. (Author)