Effect of friction model in numerical analysis of equal channel angular pressing process

During the last decade or so there has been a tremendous growth in the research and development of equal channel angular pressing (ECAP) process which was originally proposed by Segal et al. Numerical analyses are being used extensively to evaluate the effect of various die design and process parameters in ECAP. Friction is one such important parameter. Coulomb and shear friction models have been used in the numerical analysis of ECAP process and contradicting results have been reported. This study evaluates the effect of coulomb and shear friction models on the deformation pattern, strain distribution and load requirement during ECAP process and suggests which friction model should be used in the numerical analysis of ECAP process.     

Finite element analysis of rotary-die equal channel angular pressing

In this paper, the finite element method (FEM) was applied to analyze the plastic flow and strain hardening behavior of pure copper, subjected to rotary-die equal channel angular pressing (RD-ECAP) up to four passes. The die was rotated 90° counter clockwise between the passes in the simulation. The effective strain distribution and load–stroke curves were investigated. The load was increased with the number of rotary-die equal channel angular pressing passes. The results show that, plastic deformation becomes inhomogeneous with the number of passes due to an end effect, which was not found seriously in conventional equal channel angular pressing (ECAP). Especially, decreasing corner gap with increasing the number of passes was observed and explained by the strain hardening effect.     

连续等通道转角挤压对Al-Ti-C合金组织与性能的影响EI北大核心CSCD

采用连续等通道转角挤压工艺,以连续的方式对Al-Ti-C合金进行多道次挤压,通过观察微观组织演化,探讨晶粒细化机理和力学性能变化。结果表明:连续等通道转角挤压工艺可有效细化Al-Ti-C合金微观组织,晶粒尺寸减小至1μm左右,形变诱导是变形过程中最主要的晶粒细化机制;高密度位错堆积引起Al基体和TiAl_(3)界面的裂纹以及TiAl_(3)内部的空洞产生,裂纹进一步扩展贯穿整个TiAl_(3)颗粒,最终导致第二相TiAl_(3)组织的细化,同时细小的第二相TiAl_(3)组织的钉扎机制和剪切机制促进了Al基体细化;连续等通道转角挤压1道次后,合金硬度提升最明显,与原始态相比提高59.2%;之后随挤压道次的增加,硬度提升的趋势变缓,合金塑性下降,韧性提高。     

第二相粒子对ECAP挤压的2A12铝合金晶粒细化的影响

采用等径角挤压技术对2A12铝合金在室温下进行挤压,成功制备了亚微米尺度的块体铝合金材料.挤压前材料的平均晶粒尺寸约5μm,两次挤压后,平均晶粒尺寸细化至200nm左右.合金中的Al2Cu相在挤压过程中由针状变成了块状颗粒,而Al2CuMg相在挤压过程中晶粒大小基本不变.研究发现,硬颗粒Al.2CuMg对基体α-Al有剪切和割裂作用,可以促进基体的晶粒细化过程,并初步给出了晶粒细化的模型.     

Annealing twins in high purity aluminium processed by dynamic equal channel angular pressing

Annealing twins are synthesised in high purity aluminium processed by dynamic equal channel angular pressing during annealing. Annealing twins and recrystallised grains encircling the twins have specific crystallographic orientation relationships with the deformed matrix grains: approximately 35°–50°<110> for the twins and 30°–45°<100> for the recrystallised grains. Stored energy during dynamic pressing, and the crystallographic orientation between annealing twins and the deformed matrix, strongly affect twin growth during annealing.     

An experimental verification of the finite element modelling of equal channel angular pressing

Strain hardening of pure copper and friction between the sample and die channels is considered for finite element modelling. To validate the FEM results, the FEM calculated effective strain variations were compared with the hardness measurements. Simulated load–stroke curve and peak load calculations were also compared with the experimentally recorded load–stroke curve and peak load. Different stages of the load–stroke curve of the ECAP process was explained in detail. In over all, good conformity is observed between the FEM calculations and experimental results.     

摩擦力在ECAP成形时作用的有限元模拟

应用有限元方法对一种全新的可应用于板料的等通道角挤压(ECAP)方法中摩擦力的作用进行了有限元模拟.计算模拟结果表明,不同于常规的等通道角挤压中摩擦力的负面影响,在板料等通道角挤压方法中一定的摩擦力和尺寸精确的模具结构却是保证此类等通道角挤压正常进行的关键.     

等径角挤压对Al-Cu-Mg-Ag合金组织性能的影响

为研究大塑形变形对耐热铝合金的作用,采用铸冶金工艺制备了新型的Al-Cu-Mg-Ag耐热铝合金,通过显微组织观察、差热分析及硬度测试等方法,研究了等径角挤压对耐热铝合金显微组织与力学性能的影响.结果表明:通过对挤压态的Al-Cu-Mg-Ag耐热铝合金在固溶淬火后时效前进行等径角挤压变形,可获得晶粒尺寸低于2μm的块体超...     

Microstructure and mechanical properties of Cu and Cu-Zn alloys produced by equal channel angular pressing

Ultrafine-grained (UFG) Cu and Cu-Zn alloy were prepared using equal-channel angular pressing (ECAP) to investigate the effects of stacking fault energy (SFE) on microstructure evolution and mechanical properties. Combining with the previous researches, the grain refinement process of ECAP is divided into three stages based on the variation of tensile strength and plasticity. According to the influences of defects on strength and ductility during plastic deformation, the three stages are discussed in detail by considering the dislocation density, grain and twin boundaries. Besides, the impact of SFE on the strength and ductility of the UFG Cu-Zn alloys are evaluated, indicating that these two mechanical properties can be improved simultaneously in the whole ECAP process either through slightly or widely adjusting the SFE. This significant effect of SFE reflects in two aspects, one is in the microstructure evolution during ECAP processing and the other is in the subsequent tensile plastic deformation, both of which can be achieved through regulating the dislocation motion via changing the SFE.     

Finite element analysis of the effect of the inner corner angle in equal channel angular pressing

The inner corner angle (ICA) is one of the major factors affecting deformation homogeneity in workpieces during equal channel angular pressing (ECAP). In this study, the effect of the ICA on the plastic deformation behavior in ECAP was investigated using the finite element method. A round ICA induces highly inhomogeneous deformation in the head, tail, top and bottom regions of the workpiece due to increasing compressive and decreasing shear deformation components. It was found that a round inner corner with an angle up to 9° is acceptable in finite element simulations for reproducing a sharp inner corner. These results can serve as a design guide for processing and dies of ECAP.     

On the effect of acute angles on deformation homogeneity in equal channel angular pressing

Finite element calculations for strain development and deformation homogeneities under equal channel angular pressing (ECAP) considering the channel angle, friction and the channel thickness show that general phenomena characteristic of ECAP still hold when the channel angle is acute ( = 75°), in contrast to the conclusion of the recent paper on acute channel angles [A.V. Nagasekhar, Y. Tick-Hon, S. Li, H.P. Seow, Mater. Sci. Eng. A410–A411 (2005) 269–272] that formation of corner gap was not a factor for the acute channel angles.     

FEM analysis of equal channel angular processes

Much effort has been devoted to the study of the formation of superplastic in aluminum alloys on account of its cost and engineering advantages. From a mechanical point of view, the ability of a crystalline material to undergo superplastic behavior is usually linked to a submicrometer grain size. Equal channel angular extrusion (ECAE) is an innovative technique for developing ultrafine-grained microstructures by introducing a severe plastic deformation in a bulk material with no significant changes in its cross-section. Equally, equal channel angular drawing (ECAD) is an emerging technology that permits more industrial applications than the former. However, the deformations thus obtained are much lower. This work presents a study of the application of the finite elements method to this technique using two common angles of 90 and 120°. Process conditions have been modified in order to analyze the effect of friction between the dies and the billet. Moreover, experimental ECAE and ECAD methods have been carried out using 3103 Al-Mn; 5083 Al-Mg and 1370 aluminum alloys through Routes A and B.     

Effects of grain size on compressive behaviour in ultrafine grained pure Mg processed by equal channel angular pressing at room temperature

Ultrafine-grained pure magnesium with an average grain size of 0.8 μm was produced by refining coarse-grained (980 μm) ingot by multi-pass equal channel angular pressing (ECAP) at room temperature with the application of a back pressure. The compressive deformation behaviour at room temperature depended on grain size, with deformation twinning and associated work hardening observed in coarse-grained Mg, but absent in the ultrafine grained material as decreasing grain size raised the stress for twinning above that for dislocation slip. The ultrafine grained Mg showed good plasticity with prolonged constant stress after some initial strain hardening.     

Influence of equal channel angular pressing in an acute angle die with a back pressure notch on grain refinement,torsion and mechanical properties of aluminium

Severe plastic deformation improves the strength of a metal by strain hardening. Of the various severe plastic deformation processes, equal channel angular pressing proves to be the right candidate for bulk metal processing. Extensive works were carried out on equal channel angular pressing with channel angle ranging from 90° to 120 ° with or without back pressure on the exit channel. Numerical analyses suggest that reducing the channel angle below 90° would enhance the magnitude of strain imparted and, with prediction of a lesser strain homogeneity in such cases. Hence an acute angled equal channel angular pressing die with a back‐pressure notch sunken into the roof of the exit channel was designed, fabricated and was used for processing pure aluminium. Various mechanical properties of the processed materials were tested and acute angle processing imparted superior tensile strength to the work pieces in a single pass that would require several passes in a conventional equal channel angular pressing die. Substantial improvement in grain refinement and torsional properties was identified.     

ECAP细化晶粒法的仿真与分析

ECAP(Equal Channel Angular Extrusion)方法，是实现材料纯剪切变形的有效方法。本文采用有限元（FEA）分析软件ANSYS对Al的挤压过程进行仿真与分析。分析结果表明：外切角Φ、圆角半径、试样与凹模之间的摩擦系数、凹模本身的特性（如弹性模量、泊松比等）等等，对材料的变形量都有不同程度的影响。     

Texture and mechanical properties of single crystal copper during equal channel angular pressing by route C

Single crystal copper has excellent electrical and thermal conductivity, but the lower strength seriously limited its application. Traditional strengthening methods, such as alloying, will severely damage its conductivity. Severe plastic deformation is the most effective methods for increasing the metals strength and not reducing the conductivity. The microstructure and texture evolution of single crystal copper (99.999 %) during equal channel angular pressing by route C was investigated by scanning electron microscopy, X‐ray diffraction, electron backscatter diffraction and transmission electron microscopy, the mechanical properties and conductivity were tested, and the influence mechanism of texture and microstructure on mechanical properties and conductivity were analyzed. The results show that during equal channel angular pressing, the original <111> orientation gradually changed to <001>, accompany lots of low‐angle grain boundaries were formed. With strain increasing, the high‐angle grain boundaries increased gradually, and the deformation bands with <110> orientation was formed in the single crystal structure, which plays a positive role on the conductivity. After 5 passes, the tensile strength of single crystal copper increased from 168 MPa to 415 MPa by route A and 385 MPa by route C, and the elongation declined sharply from 63 % to 30 % and 27.9 %, respectively. After 16 passes, the hardness increased from 60.4 HV to 130.8 HV and the conductivity only slightly down.

     

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.     

Dependencies of grain refinement on processing route and die angle in equal channel angular extrusion of bcc materials

The efficiency of grain refinement in equal channel angular extrusion of body-centered cubic (bcc) materials is investigated based on slip activities from crystal plasticity simulations, which account for both the macroscopic and crystallographic features of deformation. It is shown that the characteristics of slip activities, especially the relative contributions of slip systems newly activated or reversed at the transitions between successive passes, vary significantly with the processing routes (A, B and C) and die angles ( = 90° and 120°). The simulations assuming {1 1 0}111 slip suggest that routes B and A lead to the most significant contributions of newly activated slip systems and hence are most efficient for grain refinement with  = 90° and 120°, respectively. Further incorporation of {1 1 2}111 slip systems leads to the highest efficiency by route B for both die angles. These predictions are in partial agreement with experimental observations in the literature. Comparison of these results with those of face-centered cubic materials reveals the relevance of crystal structure and deformation mechanism during grain refinement.     

铝粉烧结材料等通道转角挤压组织性能演变

对不同路径和不同道次下铝粉烧结材料的等通道转角挤压工艺进行了试验研究,用光学显微镜、扫描电子显微镜和透射电镜分析了粉末烧结材料在不同工艺条件下的晶粒细化规律和致密行为,并测量了挤压后试样的密度和硬度等性能.结果表明,等通道转角挤压工艺对粉末烧结材料具有很强的致密效果和细化效果,可显著提高其力学性能.在单道次变形中,大剪切塑性变形和高静水压力状态是粉末烧结材料获得良好的致密效果的关键;在多道次变形中,变形量的累积和不同的剪切特征不断地改变内部的孔隙形状,使内部基体材料进一步致密.而晶粒的细化效果则取决于变形中的静水压力、变形量和剪切特征等关键因素.     

高应变速率下等径角挤压高纯粗晶铝中的形变孪晶与退火孪晶

在室温下对铸态高纯粗晶铝进行一道次高应变率动态等径角挤压(D-ECAP)变形,利用电子背散射衍射技术(EBSD)研究挤压过程中所形成的孪晶。结果表明:利用D-ECAP能够在粗晶铝中同时制备出形变孪晶和退火孪晶,但两者在形态、Kernel平均取向差(KAM)以及与相邻晶粒的取向差三个方面存在较大差异。D-ECAP高应变率和大剪切变形使高层错能铝中形成了百微米级的形变孪晶,形变孪晶的形态为透镜状,后续变形使得孪晶界偏离∑3 60°〈111〉取向关系且KAM值主要集中于0.6°~1.8°。高应变率剪切变形下形成的大量层错和复杂的位错组态以及高形变储存能在变形温升的作用下促进了退火孪晶的形成。退火孪晶的形态较不规则,但孪晶界的取向关系更接近于∑3 60°〈111〉且KAM值主要集中于0.2°~0.5°。