In the metal forming process, a realistic frictional coefficient must be specified at the die/work piece interface. Several methods are developed to evaluate friction coefficient in large deformation processes. This paper presents the concept of friction calibration map to determine different frictional conditions between interfaces of die and billet in the upsetting process. One such map is generated for aluminum for three aspect ratios. Simulation and experimental verification of this map also attempted to show the accuracy of one map.
