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Numerical Investigation of Size Effect on Dry Friction Behavior in Micro Upsetting Process

After modifying the Wahime/Bay friction model, a new friction model suitable for micro-forming process without lubrication is established. In this model, it is shows that the friction coefficient is a function of strain hardening exponent, the normal pressure and the initial yield stress of material. Based on the experimental data, the micro-upsetting process is simulated using the proposed friction model. The simulation results are used to investigate the size effect on the dry friction behavior. It is found that the Coulomb’s friction coefficient is dropping with miniaturization of specimens when the amount of reduction is not too large.