<p>Friction at the die-workpiece interface plays a major part in controlling material flow and overall quality in Metal Forming (MF) processes. Therefore, the evaluation of friction in the MF process is necessary for the successful implementation of forming techniques. However, existing research works for evaluating the friction process did not accurately focus on the real foraging conditions. Hence, this research study presents a Spike Forging Test (SFT) for assessing friction in the hot forging of medium carbon steel. For the evaluation, the finite element simulation and experimental analysis have been conducted. The result of the investigation reveals that the spike condition is highly sensitive to both friction conditions and billet geometry, with different deformations observed across various height-to-diameter (H_o/D_o) ratios. Among the different ratios, 0.4 ratios provide the best sensitivity to frictional changes due to a balanced combination of axial and radial metal flow. Moreover, a developed calibration curve enables accurate determination of friction factors under different lubrication conditions, with strong agreement between predictions and experiments. Overall, the findings of the study show that the SFT provides the actual forging conditions compared to conventional tests. Furthermore, combining simulation with experimentation reduces trial-and-error, improves efficiency, and lowers the cost. The advantage of this process is highly useful for optimizing the forging process and improving product quality.</p>