This paper presents an improved numerical simulation of bulk metal forming processes. It takes into the account the advanced formalism of large displacements and large deformations. Also, the interface workpiece formalism in considered. Metallographic studies are conducted to determine the evolution of the micro hardness as a function of annealing time and that to characterize accurately the plastic range of aluminum alloy for a range of plasticity 120%. The obtained results of metallographic studies are used to simulate a hot upsetting under the friction law of the plastic wave. Several simulations of forging operations of an axisymmetric billet by a rigid axisymmetric conical tool are performed with ABAQUS/standard computer code and that for preheated billets from 20 °C to 500 °C. The numerical study of the evolution of the normal stress at the interface has shown that the latter is independent of the tool roughness for a temperature close to 500 °C. The numerical study also allowed us to define the three a reas of forging whatever cold; warm and hot forging. The effects of friction coefficient on the metal flow and contact pressure are numerically explored
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