The spike forging test is still commonly used although there are some new tribology test methods, but each designer\nwould like to give their own parameters. Considering the spike height difference between low friction and high friction\nas the evaluation index, an optimal spike forging test developed using finite element simulations based on orthogonal\noptimization method and sensitivity analysis of tribological conditions of selected key design parameters was carried out.\nThe spike height does not always monotonically decrease with the increase in friction factor in the scheme with improper\nparameters; therefore, the design of spike forging test should be critically evaluated before assessing tribological conditions.\nAccording to the optimized parameters, a simplified set-up of spike forging test was designed, and two retainers\nwith a clearance fit and the billet with a chamfer were prepared to position the test billet. Finally, four different tribological\nconditions, including dry polytetrafluoroethylene lubricant, multipurpose grease, VG32 oil, and dry condition, in aluminum\nforging were chosen as a case study for the optimized design of spike forging test, and correspondingly, the\nlubricating effect was distinguished.
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