Date of Award

Fall 2015

Document Type


Degree Name

Master of Science (MS)


Mechanical Engineering

First Advisor

Domblesky, Joseph P.

Second Advisor

Fournelle, Raymond A.

Third Advisor

Bowman, Anthony


An investigation was conducted to study the effects of die surface topography, specifically surface roughness and lay, on metal flow and the friction factor under lubricated hot compression. 6061-T6 aluminum rings and square bar stock specimens were compressed on H-13 tool steel platens machined with a unidirectional lay pattern to six different roughnesses between a R 10 and 240 μin. A lab based hydraulic press mounted with an experimental die set was used for all testing. Repeated trials were conducted using high temperature vegetable oil and boron nitride lubricants. Metal flow was quantified as a function of surface roughness, lay orientation, and die temperature. Approximate plane strain cigar test specimens were compressed at platen temperatures of 300 °F and 400 °F and at orientations of 0°, 45°, and 90° between the longitudinal axis and unidirectional platen surface lay. The friction factor was assessed using the ring compression test under varying platen roughness conditions and die temperatures between 250 °F and 400 °F. Results indicate metal flow is optimized at low platen roughnesses and orientations parallel to the surface lay of the platen. Die temperature was not found to influence metal flow within the temperature range investigated. The friction factor was observed to be minimized at lower die temperatures and platen roughnesses.

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