Experimental study of miniaturized tip test

A tip test was developed and used successfully for friction measurement between the billet and dies or punches for the cold forging process. In the present investigation, the test was downsized and experimentally investigated to find the size effect on test results. For the test, aluminum alloys of 2024-O and 6061-O were used and the specimen was made into a cylinder of diameter and height of 10.0mm and 5.0mm, respectively. For lubrications, VG32, VG100, grease, and corn oil were used in experiments and tests were also carried out with two different humidity conditions. A micro-hardness test was made to compare the hardness distribution with the strain distribution obtained from the finite element simulation. The load levels and tip distances were measured for Al6061-O specimen with various lubrication conditions and compared to each other to find any correlation between the two. The shear friction factors were determined for various lubrications by using the finite element simulation under the present condition.