To study the effect of friction during upsetting process.

This simulation video demonstrates how friction influences the upsetting process, a key metal forming operation. During compression, friction acts at the interface between the workpiece and the dies, significantly affecting the metal flow. By varying frictional conditions — from low to medium to high friction — we observe changes in deformation behavior, strain distribution, and the force required to forge the material. The results clearly show that higher friction restricts material flow at the contact surfaces, leading to barreling, non-uniform strain, and increased forging load. In contrast, lower friction allows smoother deformation and reduces required force. This study helps viewers understand the importance of lubrication, die conditions, and process control in forging, making it highly relevant for students, engineers, and researchers working in manufacturing and metal forming.