Aluminum-Copper binary alloys (2%, 4% & 6% by weight) were deformed (compression) between flat platens to predict the metal flow. Friction and aspect ratio (H₀/D₀ =1.0 and 1.5) are studied as process parameters.  Surface lubrication (Vacuum grease as lubricant) minimized barreling for compared to dry compression.  Non uniform deformation was observed in terms of variation in Vickers micro-hardness.  The same has been correlated with microstructural features.  Adoption of Vision system to analyze the flow behavior of materials during upsetting has been investigated by using PC based video recording system and CCD camera was used to analyze the grid deformation. Finite element software ANSYS has been applied to model, simulate, and analyze the upset forming process.  Friction coefficient, measured from Ring test was used for FEM modeling.   

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