Analysis of the maximum friction condition for green body forming in an ANSYS environment

•Performance of commercial FEM software to model large plastic deformation under high friction has been questioned.•Maximum friction law (Tresca condition with the parameter m = 1) was used to account for such regime.•It was shown that singular strain rate predicted by theory cannot be properly realised within the standard approach.•Some practical advices for the users to model were produced.

Axisymmetric extrusion of an elasto-plastic material with the maximal shear stress condition between the material and the forming tool is considered. The elastic component of deformation is assumed negligible in comparison with its plastic part. Challenges related to the numerical modeling of such a problem with the commercial software ANSYS are identified. In conclusions, recommendations for treating the problem are proposed.