AbstractThe upsetting‐sliding test where a rigid contact tool induces localised plastic deformation on the surface of a test piece was developed to identify the friction coefficients and lubrication failures encountered in metal‐forming processes. The test has two consecutive stages. In the first, upsetting phase, the contact tool comes into contact with the workpiece and makes an indentation of some hundredths of a millimetre. In the second, sliding phase, the contact tool slides along the workpiece surface.A methodology, based on mechanical analysis of this test using the finite element method, was devised to determine the parameters needed to simulate pre‐defined mechanical magnitudes at the contact tool/workpiece interface during the sliding phase. The present work shows that applying this methodology to the upsetting phase of the test reduces the number of numerical simulations required and, consequently, the cost of such a determination, whilst maintaining the test's high level of representativ
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