Tests results on lubrication for metal forming in laboratories are sometimes not applicable to actual processes; this may be attributed to heat generation, which is influenced by the length of contact between the tool and workpiece. An attempt is made to investigate the effect of contact length, the so-called size effect, on lubrication in a simulation test for steady-state metal-forming processes. Lubrication appears to change with contact length, with other conditions being unchanged; the bite angle at which lubrication becomes less effective is found to be smaller for larger contact length.

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