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The purpose of presented study is to investigate the development of the barreling obtaining the variation of the surface area during upsetting of cylindrical specimens for various metals and alloys.

Variations of the surface areas were first obtained analytically using mathematical equations for uniform and non‐uniform upsetting. Barreling contours were accepted as circular segments in the development of the equations. In the experimental part of the study, barreling radii and other related dimensions of upset specimens were measured and inserted into the developed equations in order to obtain the variations of total specimen surface areas.

As it is expected, barreling effects the variation of total surface areas of the specimen. It can be concluded that the total surface area first decreases at low upset ratios for all the test materials and then begins to increase as the upset ratios increases. Consequently, total surface areas for non‐uniform upsetting are always smaller that those of uniform upsetting.

Five kinds of materials were used in the experimental part of the study. Specimens were also upset without lubrication. A relatively slow hydraulic press was used during the experiments with 5 mm/s ram speed.

Although the study has not direct implications for the practical purposes in forging area, results can be used as a very useful source of information for researchers in this field to plan their studies. Variation character of total surface area obtained in the study may give useful data in analyzing the deformation patterns in upsetting.

The effects of barreling on the material behavior in upsetting for non‐uniform conditions were analyzed with respect to variation of total specimen surface area. This point of view may be extended for different materials and friction conditions.

The purpose of this paper is to determine the influence of surface roughness on materials flow of various materials using grid lines during cold forming.

The study is focused on the investigation of the influence of the surface roughness on the materials flow for different materials using grid lines in the upsetting. Stainless steel, SAE 1020 steel, commercially pure aluminum, commercially pure copper and CuZn₄₀Pb₂ brass are used as the test materials. Upsetting process is applied to the cylindrical specimens using the flat end dies. Strain distributions on the free surfaces of cylindrical upset specimen are measured for different upsetting reductions. Strain distributions on the free surfaces are obtained by the measurements of the dimensions of the square grid elements before and after the upsetting process. Experimental results are placed into graphical plots.

It is found that surface roughness is effectual on the strain changes on the free surfaces with the increasing deformation ratio for especially two types of steel specimens. There has been no considerable effect on aluminum, copper and brass specimens.

It would be interesting to search the surface roughness, R_sk and other parameters describing the bearing properties of the surface of more materials. Future work could be concentrated on the cold forming of these materials.

Different forming technologies are nowadays widely applied in mass production of mechanical components for needs of transportation, electronics, household appliances, etc. In order to reduce costs, manufacturers are trying to minimize additional machining and therefore to implement the influence of surface roughnesses on materials flow of various materials.

The main value of this paper is to contribute to studies on the influence of surface roughness on materials flow of various materials.

Barreling contour variations on the free surfaces of cylindrical upset specimen are to handle measuring for different upsetting reductions and different lubrication conditions in this study. The purpose of this paper is to address this issue.

The materials flow for various materials using different lubricants in upsetting was investigated in this study. SAE 1020 steel, commercially pure copper and CuZn40Pb2 brass were used as the test materials. Upsetting process was applied to the cylindrical specimens using flat end dies. Three types of lubricants, namely grease, graphite and SAE 40 oil, were used in this study. Experiments were performed using a hydraulic press, which has 5 mm/s ram speed, and with a capacity of 150 metric tons.

Variations of barrel radius change clearly with increasing deformation ratio depending on lubricant type. Radius values are different to each other for SAE 1020, Cu and brass specimens. It was understood that surface roughness effect is negligible at material types. The highest radius values were obtained for the brass among all the materials for the same deformation ratio. The materials flow is hard for brass specimens because of its brittleness which is due to cold drawing so its barrel radii are high. On the contrary, SAE 1020 and copper are more suitable for the plastic deformation. As shown in the Figures, the higher radius values were obtained especially with grease lubricant for brass specimens.

It would be interesting to search material flow for different materials and lubricants. It could be a good idea for future work could be concentrated material flow on upsetting using different lubricants.

The friction at the faces of contact retards the plastic flow of metals and the surfaces and in its vicinity. A conical 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 in the form of a barrel. This demonstrates that the metal flows most easily towards the nearest free surface which is the point of least resistance. However, the use of lubricants reduces the degree of bulging and under the conditions of ideal lubrication, the bulging can be brought down to zero.

The main value of this paper is to contribute and fulfil the detailed the dependency of barrel radius on material type by upsetting of specimen of various materials using different lubricants that are being studied so far in the literature.

The purpose of this paper is to apply the upsetting process to cylindrical specimens using flat end dies in which three types of lubricants were used. In many industrial processes, friction and lubrication have major advantages and are key during the metal forming process. Upset forging is a process which increases the diameter of the work-piece by compressing its length.

The materials flow for various materials using different lubricants in upsetting was investigated in this study. AISI 304 austenitic-stainless steel and commercially pure aluminium (Al99.7) were used as the test materials. The upsetting process was applied to the cylindrical specimens using flat end dies. Three types of lubricants, namely, grease, graphite and SAE 40 oil, were used in this study. Experiments were performed using a hydraulic press, which has 5 mm/s ram speed, with a capacity of 150 metric tons. On the other hand, finite element methods (FEMs) have been carried out to analyse the forming performance for displacement prediction in the barrelling process.

The results showed that the measured radius of the curvature of the barrel seemed to confirm the calculation values used before the initiation of the experimental process. It has been observed that the surface roughness had no considerable effect on the barrelling contour changes on the free surfaces, as it showed an increasing deformation ratio for all materials and lubricant types. However, minimum friction at the interface seems to occur with the grease lubricant. The present analyses show that FEMs, which can be used in the rapid prediction of required barrelling process displacements, are more suitable for use in a pressure distribution analysis for the development of the barrelling radius.

It would be interesting to search the material flow for more different materials and lubricants. It could be a good idea if future work could be concentrated on the material flow on upsetting by using different lubricants.

Open-die forging, which is also known as the upsetting process, is one of the simplest forging operations used in bulk deformation processes. This operation can be explained as a solid work-piece which is positioned between two flat dies, and then with the aid of compression, the height of the work-piece is reduced under controlled working parameters during the upsetting process, in which friction and surface roughness are the major parameters playing an important role on the material flow. In a cold upsetting process, one of the undesirable conditions is that barrelling occurs as a consequence of friction between the work-piece and the die surfaces. The existence of this frictional constraint directly affects the plastic deformation of the work-piece, as friction causes barrelling in upsetting processes. However, it has been observed that the use of lubricants reduces the degree of bulging.

This paper will be useful for industrial applications.

The main value of this paper is to contribute and fulfil in detail the material flow of various materials using different lubricants that are being studied so far in the literature.