Optimal tool angles for equal channel angular extrusion of strain hardening materials by finite element analysis

Equal channel angular extrusion (ECAE) is a novel deformation process capable of imparting a large amount of plastic strain to bulk material through the application of uniform simple shear. ECAE die geometry, material properties and process conditions influence the shear deformation behavior during extrusion that in turn governs the microstructure and mechanical properties of the extruded materials. Finite element analysis, the most appropriate technique was used to analyze the deformation behavior of extruded materials without neglecting important and realistic factors like strain hardening behavior of the material, frictional conditions and speed of the process. In this study the deformation behavior of material, dead zone/corner gap formation and strain homogeneity achieved in the samples during ECAE were studied by using commercial finite element code Abaqus/Explicit. The influence of tool angles, strain hardening behavior of material and friction between the billet and die was considered for simulations. Results showed that the optimal strain homogeneity in the sample with lower dead zone formation, without involving any detrimental effects, can be achieved with channel angle of 90° and outer corner angle of 10°.     

Optimum groove pressing die design to achieve desirable severely plastic deformed sheets

In this paper, considering the problems of common finite element (FE) codes that consider simple constitutive equations, a developed FE code that considers a new constitutive model is used to simulate the behavior of copper sheets under severe plastic deformation (SPD). The new proposed constitutive model, that considers dislocation densities in cell interiors and cell walls of material as true internal state variables, can investigate all stages of flow stress evolution of material during large plastic deformations and also can explain the effects of strain rate magnitude on the mechanical response of material, during room temperature SPD. The proposed FE analysis is used to investigate the effects of die design on the property of SPDed sheets by groove pressing (GP) processes. To do so, the GP processes through existent designations of dies are simulated and a good agreement between the modeling results and experimental data is obtained. In addition, a new die design is proposed that can eliminate the problems of the existent designations of dies and can produce the sheets with higher strength and more uniform hardness.     

Microstructure and Properties of Al-6061 Alloy by Equal Channel Angular Extrusion for 16 Passes

The experimental researches on Equal Channel Angular Extrusion (ECAE) process of commercial available Al-6061 alloy were conducted and the grain refinement after ECAE processing was investigated. Sixteen passes of ECAE processing at room temperature were conducted and the relationship of grain refinement with extrusion pass was established. The property enhancements after ECAE processing including ultimate tensile strength and Vickers microhardness were investigated to determine the effects of the number of ECAE passes on the mechanical properties of the extruded samples. The research presents a whole picture of ECAE processing of the alloy for up to 16 passes.     

Texture evolution in equal-channel angular extrusion

The focus of this article is texture development in metals of fcc, bcc, and hcp crystal structure processed by a severe plastic deformation (SPD) technique called equal-channel angular extrusion (ECAE) or equal-channel angular pressing (ECAP). The ECAE process involves very large plastic strains and is well known for its ability to refine the grain size of a polycrystalline metal to submicron or even nano-size lengthscales depending on the material. During this process, the texture also changes substantially. While the strength, microstructure and formability of ECAE-deformed metals have received much attention, texture evolution and its connection with these properties have not. In this article, we cover a multitude of factors that can influence texture evolution, such as applied strain path, die geometry, processing conditions, deformation inhomogeneities, accumulated strain, crystal structure, material plastic behavior, initial texture, dynamic recrystallization, substructure, and deformation twinning. We evaluate current constitutive models for texture evolution based on the physics they include and their agreement with measurements. Last, we discuss the influence of texture on post-processed mechanical response, plastic anisotropy, and grain refinement, properties which have made ECAE, as well as other SPD processes, attractive. It is our intent to make SPD researchers aware of the importance of texture development in SPD and provide the background, guidance, and methodologies necessary for incorporating texture analyses in their studies.     

A modification on ECAP process by incorporating torsional deformation

In the present study, integration of equal channel angular pressing (ECAP), as a well known severe plastic deformation (SPD) technique, and torsion deformation, is studied by using three dimensional finite element analysis. This process is to be named as torsional-equal channel angular pressing (T-ECAP). In this modification a part of the exit channel in the ECAP die is rotating around its axis, to impose extra shear strains to the samples. To study deformation behavior in the T-ECAP process, three-dimensional finite element analysis (FEA) was carried out by using the elasto-plastic finite element analysis ABAQUS/Explicit Simulation. To investigate the validity of the simulation results, experimental studies were furthermore performed on commercially pure aluminum (AA 1050). Vickers hardness test was used to determine the distribution of hardness on both normal and longitudinal sections of the deformed samples with respect to the exit channel of the die. The hardness test results showed more uniform distribution of hardness in both sections of the T-ECAP processed samples regarding the ones produced by ECAP process. The load requirement comparison for performing both processes showed lower value for the T-ECAP with respect to the ECAP process. The simulation results for the strain values showed higher magnitude and more uniform distribution for the T-ECAP with respect to the ECAP process.     

Effect of 2θ-Punch Shape on Material Waste during ECAE through a 2θ-Die

This article mainly focusses on the improvement of metal forming die tooling for equal channel angular extrusion (ECAE) processes through nonrectangular 2θ-dies of classical Segal geometry. The technological appropriateness of workpiece deformation through 2θ-dies using inclined oblique 2θ-punches has been evaluated with the introduction of physical simulation techniques. It has been shown experimentally that for the best efficiency, the geometric condition required for the taper angle of the inclined oblique punch is equal to the 2θ angle between the inlet and outlet channels of the angular die. Physical simulation shows that the application of an oblique inclined 2θ-punch provides workpiece dead zone area downsizing and macroscopic rotation reduction during ECAE. The use of numerical finite element modeling simulation also confirms the usefulness of the oblique inclined 2θ-punch for increase of the utilization ratio and decrease of the maximum deformation and unevenness of deformation distribution.     

Development of a novel severe plastic deformation method for tubular materials: Tube Channel Pressing (TCP)

A new severe plastic deformation (SPD) method entitled Tube Channel Pressing (TCP) is proposed. In this study, the ability of TCP on strength improvement and grain refinement is assessed. This method is based on pressing a tube through a tubular channel die with a neck zone. Utilization of a mandrel fitted inside the tube prevents the crumpling of tube and preserves its initial dimension. Due to the symmetric design, after one pass, the die is rotated upside down and the second pass is applied by pressing the tube in inverse direction. Ultimate strength of a commercial purity aluminum tube after 5 successful passes is improved to 2 times of the initial strength. Analytical calculations and simulation of this process accompanied by commercial finite element code ABAQUS/Explicit demonstrate that the total average equivalent strain of 1.2 is imposed in each pass. Furthermore, hardness distribution through tube thickness is assessed. Then, ability of TCP in grain refinement of tubular samples after each pass is determined.     

Analytical modeling of material flow in equal channel angular extrusion (ECAE)

We provide analytical forms for the plastic deformation and velocity gradients associated with a single pass of equal channel angular extrusion (ECAE). Three cases of plastic deformation are considered: ideal simple shear, a plastic deformation zone (PDZ) in the shape of a central fan of angle β_m, and a two-part PDZ consisting of a central fan in the ‘upper’ region and a low intensity shear deformation in the ‘lower’ region. The analysis for simple shear considers a general die angle Φ, whereas the other two cases only consider Φ=90°. The tensors for deformation and velocity gradients completely describe the deformation, such as the directions and magnitudes of material stretching and rotations. From this analysis, one can calculate deformation and texture evolution. Texture evolution during flow through the central fan zone involves continuous rotation of the texture components causing the texture developed at the end of the extrusion to be rotated relative to the ideal simple shear case. The analysis of the two-part zone suggests inhomogeneity in texture evolution, in which features of the initial texture are retained and rotated in the lower region, while they are nearly erased in the upper region. These analytical flow patterns for a single pass can be repeatedly applied for any number of passes of any ECAE route.     

Interface sheet-constrained groove pressing as a modified severe plastic deformation process

In this paper, a new severe plastic deformation (SPD) process entitled interface sheet-constrained groove pressing (ISCGP) as a new variant of conventional CGP has been developed for producing ultrafine-grained metallic materials. In this process, repetitive shear deformation is imposed into the sheet material by utilising symmetrically grooved die along with two interface sheet on both sides. To study the applicability, mild steel sheets were processed by both ISCGP and CGP processes, and mechanical and microstructural properties of the processed samples were investigated. The results show a considerable improvement in mechanical properties including hardness, yield strength, and ultimate tensile strength, though the ductility sacrifice was reduced. Comparing ISCGP and conventional CGP revealed interesting results, which are shown that ISCGP can result in better surface quality and ductility.     

Design and mechanical property analysis of ultrafine grained gears from AA5083 previously processed by equal channel angular pressing and isothermal forging

In this present study, the isothermal forging of two different gears is carried out from material previously deformed by the severe plastic deformation (SPD) process known as Equal Channel Angular Pressing (ECAP). At present, there are only a few studies which use this material predeformed that exhibits improved mechanical properties as a result of the SPD process for use in subsequent processes or applications. The design and optimization of the die geometry required for the isothermal forging of gears are shown and both microhardness and microstructure are compared when these forged gears are obtained from annealed material (N0) and ECAP-processed material (N2). With this present research work, it is demonstrated that there is an improvement in forgeability and microhardness as well as a decrease in the grain size of the material predeformed by SPD.     

Review of principles and methods of severe plastic deformation for producing ultrafine-grained tubes

Severe plastic deformation (SPD) is known to be the best method for producing bulk ultrafine-grained and nanostructured materials with excellent properties. Different SPD methods were developed that are suitable for sheet and bulk solid materials. During the past decade, efforts have been made to create effective SPD processes suitable for producing cylindrical tubes. In this paper, we review SPD processes intended to produce ultrafine-grained and nanostructured tubes, and their effects on material properties. The paper will focus on introduction of the tube SPD processes, and then comparison of them based on their advantages and disadvantages from the viewpoints of processing and properties.     

Mechanical Behavior Enhancement of AM60/Al2O3p Magnesium Metal–Matrix Nanocomposites by ECAE

The effect of equal channel angular extrusion (ECAE) on the mechanical behavior of AM60/Al₂O_3p magnesium metal–matrix nanocomposites was investigated. ECAE is a useful technique to produce bulk nanostructured materials through severe plastic deformation. The present magnesium metal–matrix composites (Mg MMCs) with 1 wt% nanosized Al₂O₃ particles for ECAE were fabricated using stir-casting method. The significantly enhanced mechanical behavior of AM60/Al₂O_3p magnesium metal–matrix nanocomposites at room temperature, for instance, yield strength (YS), ultimate tensile strength (UTS), and ductility, can be obtained after ECAE process. The AM60/Al₂O_3p MMC after 4 passes of ECAE exhibited greater YS, UTS, and ductility (+135%, +107%, and +245% increase, respectively) than those of as-cast AM60. Experimental results show that the AM60/1wt %Al₂O_3p MMC after 4 passes of ECAE exhibits the superior mechanical behavior.     

The effect of deformations passes on the extrusion pressure in axi-symmetric equal channel angular extrusion

The most applicable configuration of the equal channel angular extrusion (ECAE) dies is the axi-symmetric one. However, most of the previous analytical solutions are focused on the plane strain conditions. In this research, an upper bound model is used to investigate the deformation of the material during axi-symmetric ECAE. The analysis considers the effect of die angle, friction between the sample and the die walls, and the angle of the outer curved corner of the die, on the extrusion pressure. It is found that increasing the die angle and outer curved corner angle and decreasing the friction coefficient results in decreasing extrusion pressure. The proposed model is verified using two dies of the same die angle and different outer curved corner angles. The applicability of the solution in the ECAE process with more than one pass is investigated and the difference between the theoretical and experimental results are discussed.     

Microstructural and mechanical properties of commercially pure aluminum subjected to Dual Equal Channel Lateral Extrusion

This paper aims to provide an introductory insight about “Dual Equal Channel Lateral Extrusion”, a counterpart of “Equal Channel Angular Extrusion”. The process is implemented to severely refine the microstructure of aluminum slabs. Comparisons of macroscopic parameters as average straining and large scale distribution of strain, as well as process loads reveal the supremacies and short comings of DECLE with respect to ECAE. DECLE shares a relatively similar geometry of deformation with that of ECAE. The advantages of this process with respect to ECAE are: (i) more intensive strains attainable per pass, and (ii) less extruding power needed for a given sample size. Nonetheless, less homogeneous strain per pass is seen in case of DECLE. TEM inspections revealed remarkable refinement of the microstructure through out the process and also some recrystallization at the final passes. Hardness tends to increase through successive passes to a limiting value beyond which there appeared a decline associated with intense recovery and the recrystallization observed. Compression tests exhibit the same trend, viz. a general rise in strength followed by a decrease in work hardening with increasing number of passes, leading to uniform microstructure and hardness after 9 passes.     

Properties of AA6061 Processed by Multi-Axial Compressions/Forging (MAC/F)

Multi-axial compressions/forgings (MAC/F) were conducted at room temperature to obtain severe plastic deformation (SPD) of AA6061 alloy. Microhardness measurements taken across the cross-section of each of the MAC/F processed samples indicated that the hardness distribution is nonuniform during initial compressions/forgings and becomes uniform with subsequent compressions. Microhardness and tensile testing showed that the hardness, yield strength, and elongation of the MAC/F processed material followed similar trends to that for AA6061 processed by equal channel angular pressing (ECAP). The MAC/F material exhibited high strain rate sensitivity and high percentage of elongation to failure in the temperature range of 300-350°C. This observation is in agreement with the high formability of SPD-processed AA6061 over the same temperature range.     

Influence of the supersaturated silicon solid solution concentration on the effectiveness of severe plastic deformation processing in Al-7 wt.% Si casting alloy

A comparative study of room temperature severe plastic deformation (SPD) of a hypoeutectic Al-7 wt.% Si casting alloy by high pressure torsion (HPT) and equal channel angular pressing (ECAP) has been performed. Microstructural parameters and microhardness were evaluated in the present work. Three different initial Si solid solution contents have been considered: as cast (C sample, 1.6 wt.% Si), annealed and quenched (Q sample, 1.2 wt.% Si) and annealed and furnace cooled (S sample, 0.7 wt.% Si). The samples processed by ECAP have smaller average Si particle sizes (0.9-1.7 μm), than those for samples processed by HPT (2.4-4.4 μm). The initial supersaturated Si solid solution is the major factor affecting the microstructure and the mechanical properties of the material. Fine deformation-induced Si precipitates from the supersaturated solid solution were responsible of the large grain refinement obtained by both SPD processing methods, which was considerably higher than that reported for pure aluminium. Q samples, processed by both SPD methods, containing an intermediate concentration of Si in solid solution, show the highest hardness due to the finest and most homogeneous microstructure. The finest and homogeneous grain size was ∼0.2 μm for the HPTed and ∼0.4 μm for the ECAPed Q samples.     

Enhanced grain refinement and mechanical properties in a severely plastic deformed Ni-30Cr alloy

The present study was carried out to evaluate the microstructures and mechanical properties of severely deformed Ni-30Cr alloys. Cross-roll rolling (CRR) was introduced as a severe plastic deformation (SPD) process. Ni-30Cr alloy sheets were cold rolled to 90% thickness reduction and subsequently annealed at 700 °C for 30 min to obtain the recrystallized microstructure. Electron back-scattered diffraction (EBSD) was introduced to analyze grain boundary character distributions (GBCDs). The application of CRR to the Ni-30Cr alloy effectively enhanced grain refinement through heat treatment; consequently, the average grain size was significantly refined from 33 μm in the initial material to 0.6 μm. This grain refinement directly improved the mechanical properties, in which yield and tensile strengths significantly increased relative to those of the initial material. We systematically discuss the grain refinement and accompanying improvement in mechanical properties in terms of the effective strain imposed by CRR relative to conventional rolling (CR).     

Process and die design for rod extrusion of γ iron

This study is related to materials modeling and die and process design of rod extrusion of γ iron. Strain dependent rate power law is used for materials modeling whose coefficients are arrived at through genetic algorithm (GA). Die profile of the rod extrusion process is optimized to produce products of desirable microstructure at maximum production speed and minimum left out material in the die. The design problem is formulated as a nonlinear programming problem which is solved using GA. Selection of the processing parameters is carried out using dynamic materials modeling (DMM). Using this approach rod extrusion process of γ iron is successfully designed. FE simulation on the optimum profile is also attempted to study deformation behaviour and load requirement.     

Investigation of material deformation in multi-pass conventional metal spinning

This paper reports a study on material deformation during a multi-pass conventional spinning. A Finite Element (FE) analysis model has been developed based on a 5-pass conventional spinning experiment. The explicit Finite Element solution method has been used to model this multi-pass spinning process. Effects of mass scaling and reduced integration linear element used in the FE simulation have been evaluated by using various energy histories obtained from the FE analysis. The numerical results suggest that among three tool force components the axial force is the highest while the tangential force is the lowest. Certain correlations have been found between the FE analysis results and measured dimensions of the spun part. The blank thickness decreases after each forward pass and there are almost no thickness changes during the backward pass. Stress distributions of the local forming zone of the workpiece in both forward and backward passes have also been analysed, which gives an insight into the material deformation during the spinning process.     

非连续增强金属基复合材料剧烈塑性变形行为研究进展

综述了非连续增强金属基复合材料剧烈塑性变形(SPD)行为的研究进展,系统阐述了等径弯曲通道变形(ECAP)、高压扭转(HPT)、多向锻造(MF)、累积叠轧(ARB)和循环挤压压缩(CEC)5种SPD的加工原理和方法。集中介绍了这些方法在铝基、镁基、铜基和钛基等金属基复合材料方面应用的研究进展。重点介绍了金属基复合材料SPD的微观组织演化和变形力学行为,详细阐明了金属基复合材料SPD机制以及超细晶形成机理,指出了金属基复合材料在SPD中存在的深层次问题及发展趋势,展望了利用SPD方法制备超细晶非连续增强金属基复合材料的应用前景。