In upset forging operations the pridiction of load and metal flow has been considered very important, since it makes a great influence on the deformed configurations, mechanical properties and surface defects.
Upset forging of non-circular blocks are characterized by three-dimensional deformation with sidewise spread in the plan perpendicular to the central axis as well as axial bulging along thickness.
In practical cases, the frictional conditions and surface area at the top and the bottom surface of the billet are different.
In this study a simple kinematically admissible velocity field for the three-dimensional upset forging of prismatic and non-prismatic blocks is proposed considering different frictional conditions at the top and bottom surface of the billet.
From the proposed velocity field determined the forging load and the deformed configurations by minimizing the total power at each step of the height reduction.
In order to show the validity of this theory experiments are carried out room temperature with annealed carbon-steel for different billet shapes and frictional conditions.
