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A physically-based friction model is developed based on the ball-on-disc test results. The model is verified by using double action extrusion tests. Good agreements between the FE predictions and experiments have been obtained, in terms of the extrudate length and steady-state extrusion load, indicating that ball-on-disc test is an effect way of characterizing the friction for the bearing channel of hot extrusion dies. The nature of friction in the bearing channel can be summarized as a pressure dependant process: formation of isolated adhesive junctions, adhesive junctions growth and coalescence of adhesive junctions. ⺠Ball-on-disc tests can be used to characterize the friction in the bearing channel of aluminium extrusion dies. ⺠The friction in the bearing channel is a pressure dependant process. ⺠At low contact pressure: formation of isolated adhesive junctions. ⺠At medium contact pressure: adhesive junctions growth. ⺠At high contact pressure: coalescence of adhesive junctions.
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