摩擦系数对四对轮CR-ECA大应变技术的影响

集成传统轧制(conventional rolling)和等通道转角变形(equal channel angular deforma-tion)的新型大应变技术(CR-ECA大应变技术),是一种实现材料连续塑性大变形的有效手段。利用三维有限元分析软件Deform_3D对4对轮CR-ECA大应变技术进行了仿真计算。研究了4对轧制轮在不同摩擦系数下对工件应变、轧制轮扭矩及出口速度的影响。结果表明:摩擦系数是一个重要的技术参数;工件内部应变大小随着摩擦系数的变化而变化;随着摩擦系数的逐渐增大,轧制轮总扭矩逐渐增加,驱动性能提高;出口速度呈逐渐增大趋势,生产效率逐渐提高。     

A numerical and experimental study on tubular channel angular pressing (TCAP) process

Tubular channel angular pressing (TCAP) is a new and novel severe plastic deformation (SPD) technique suitable for fabrication of bulk nanograined tubular materials. There are several parameters in the TCAP process. The present paper investigates the effects of curvature angles, deformation ratio (maximum radius during TCAP/initial radius) and deformation direction on the plastic deformation behavior, strain homogeneity and required loads in TCAP processing. The results showed that higher curvature angles (?? ₁ and ?? ₃) leads to better strain homogeneity while have not having any significant effect on the process loads. Also, at the second curvature angle of 90°, the best condition is achieved with good strain homogeneity and lower load requirements rather than lower angles. Investigation of deformation direction showed that inlet deformation direction causes tube thinning at the end of the process, and thus, using the inlet case is not recommended.     

Modeling of the processing force for performing ECAP of circular cross-section materials by the UBM

Equal channel angular extrusion or pressing (ECAP) is a process used to impart severe plastic deformations (SPD) (ε?<<?1) to materials with the aim of improving their mechanical properties by reducing the grain size. In this study, an analytical modeling of the ECAP processing force required, taking circular cross-section for ECAP dies into consideration, is developed where non-strain hardening materials are processed. To obtain the equation that relates the geometry and required force, the upper bound method was used after taking an appropriate and admissible field into consideration. In addition, a comparison between analytical methods and experimental results was made. In order to perform the experimental tests, an F-1050-AA (F means as fabricated) was selected and processed at room temperature. This alloy has a yield stress of 70?MPa and an insignificant strain hardening. The experimental results obtained agree closely with those provided by the analytical formulation. With this study, it is possible to have an analytical approach to the required force for performing the ECAP process. This could help scientists and practical engineers involved in SPD processes such as ECAP, to optimize ECAP dies and the process itself thanks to the knowledge of the analytical expressions of the required force.     

Employing severe plastic deformation to the processing of electrical discharge machining electrodes

The tool electrode has a significant role in electrical discharge machining (EDM) performance, as it affects machining efficiency, surface quality and the geometrical accuracy of the machined component. This study presents a new approach for developing a pure copper electrode using severe plastic deformation (SPD) to enhance the machining characteristics during EDM. Equal channel angular pressing (ECAP) is selected because it is the most successful SPD method of processing bulk materials. Finite element analysis, microstructural assessment as well as nanoindentation tests are carried out to determine the behavior of pure copper after one and two ECAP passes. The effectiveness of EDM when using ECAP-treated electrodes is evaluated by introducing new techniques of measuring the volumetric overcut (VOC) and corner sharpness. In addition, tool wear rate (TWR), material removal rate (MRR), electrode wear ratio, surface roughness, surface crack density and the critical crack zone are studied. The results emphasize that an electrode subjected to one pass of ECAP can enhance the workpiece accuracy by decreasing the VOC and increasing corner sharpness by 13 and 66%, respectively. It is also revealed that the nanohardness enhancement following ECAP leads to lower TWR and electrode wear ratio. An investigation of the surface characteristics indicates a thinner recast layer is achieved when using one ECAP pass-treated electrode, which leads to 26% lower surface crack density.     

等通道弯角多道次挤压工艺累积变形均匀性研究

通过等通道弯角挤压(Equal channel angular pressing,ECAP)工艺累积足够的变形制备块状超细晶粒材料(亚微米或纳米微观结构材料)。采用节点映射法将前一次有限元分析终了结果准确映射到下一次挤压初始阶段的相应节点,实现等通道弯角多道次挤压过程有限元分析。通过有限元模拟不同模具拐角的等通道弯角多道次挤压工艺,获得相应挤压件累积等效应变分布及其规律,为ECAP挤压件晶粒均匀细化提供合理的模具设计与工艺路线。     

层错能在剧烈剪切变形时对晶粒细化的影响

基于等通道角挤压晶粒细化技术,研究不同材料在相同工艺条件下为什么其晶粒演化过程会出现较大的差异,提出晶体结构与层错能在等通道角挤压过程中的剧烈剪切变形对纳米/超细晶粒组织塑性变形及晶粒细化机制的影响。试验采用中低层错能的面心立方晶格纯铜和中高层错能的体心立方晶格中碳钢作为试验材料,挤压工艺采用冷挤压和Bc工艺路径。试验结果表明,中高层错能的体心立方晶格金属是以交滑移和位错分割方式使晶粒细化;中低层错能的面心立方晶格金属是以位错分割和孪生方式使晶粒细化。金属层错能越高,剧烈剪切变形时交滑移作用越大,晶粒细化的速度也越快。体心立方结构的钢在等通道角挤压四道次后可获得均匀的纳米/超细晶粒组织,而面心立方结构的铜挤压八道次后才可获得均匀的超细晶粒组织。     

多目标质量的粉末包套等通道挤扭成形致密工艺参数优化

剧烈塑性变形法—挤扭以剪切塑变为主变形方式,成形工艺复杂,影响因素很多,难以精确地建立工艺参数与成形质量之间的关系;选取优化合理的工艺参数匹配是材料尤其是粉末材料成形无破裂、塑性好、致密化程度高等成形质量的关键。以等通道横截面扭转角、螺旋角、摩擦因子、挤压速度、初始相对密度为自变量,正交试验为设计方案,对纯铝粉末烧结材料进行一道次包套等通道扭挤数值模拟,获得以等效塑性应变、静水压力、最大损伤值、相对密度数据,通过层次分析法计算多质量目标的权重,运用追踪点法和灰色系统理论的灰色关联度优化工艺参数,使设计目标值达到等效应变最大、静水压力最大、最大损伤值最小、相对密度最大。模拟和试验结果表明,运用多目标优化组合参数进行等通道挤扭成形能使纯铝粉末体材料迅速地形变累积,静水压力提高,损伤值显著地减小,致密效率高,晶粒明显细化,提高了材料综合质量。     

Tribological properties of the AZ91D magnesium alloy hardened with silicon carbide and by severe plastic deformation

Results of investigation of the tribological contact characteristics of R18 tool steel in interface with AZ91D magnesium alloy hardened with SiC disperse powder filler and by severe plastic deformation (SPD)—specifically, equal-channel angular pressing (ECAP)—are presented. It is established that introduction of the SiC powder filler into the magnesium alloy increases the friction coefficient and reduces the wear rate. The size and volume of the powder filler particles, the normal load, and the relative sliding velocity influence these tribological characteristics. SPD of the original material leads to reduction of the molecular component of the friction coefficient.     

多模式超声振动等径角挤压超细晶纯铝成形机理研究

超细晶金属材料由于具有优异的力学性能,特别适合微小金属零件的塑性成形。大塑性变形法是制备超细晶金属材料的常用方法,等径角挤压法被认为是最具有发展前景的大塑性变形方法之一。传统等径角挤压需要通过多道次的应变量累积来获得超细晶材料,制备效率较低。将超声振动与等径角挤压过程相结合可以有效减小挤压成形载荷,提高等径角挤压制备超细晶的性能和效率。现有研究主要采用工具辅助超声振动模式,提出并研发基于工件辅助超声振动模式的等径角挤压成形工艺,并对不同超声振动模式1070纯铝等径角挤压成形机理进行对比研究,研究工具超声振动和工件超声振动两种不同振动方式对晶粒道次细化能力的影响规律。结果表明,随着超声功率的增大,工具超声振动和工件超声振动的超声软化效应逐渐增强,能更大幅度降低等径角挤压成形力,并提高晶粒道次细化能力。工件超声振动比工具超声振动更有利于吸收超声能量,从而能更有效提升超细晶金属的制备效率。     

摩擦对大型等通道转角压最大挤压载荷的影响

采用Deform-3D有限元软件对大型等通道转角压(Equal channel angular pressing,ECAP)进行动态计算仿真模拟,并进行试验研究,重点考察变形体与模具间摩擦因数和模具水平通道扩口直径对挤压载荷的影响。模拟结果表明,剪切摩擦模型适合用于ECAP变形仿真模拟计算,摩擦因数对大型ECAP的最大挤压载荷具有很大影响,随着摩擦因数的增加,最大挤压载荷急剧增加;摩擦因数μ=0.6(近似于铝和钢干摩擦)时的挤压载荷是摩擦因数为0时挤压载荷的5.1倍;增加出口通道扩口端的直径,当μ<0.6时,对最大挤压载荷几乎没有影响,而当μ>0.6时,可以明显降低最大载荷值,但也不是出口通道扩口直径越大其对应的挤压载荷就越小。试验研究表明,大型ECAP必须想办法降低摩擦才能实现批量化生产,试验和仿真的最大挤压载荷吻合。     

Structure and microstructure evolution of Al–Mg–Si alloy processed by equal-channel angular pressing

An ultrafine grained Al–Mg–Si alloy was prepared by severe plastic deformation using the equal-channel angular pressing (ECAP) method. Samples were ECAPed through a die with an inner angle of Φ = 90° and outer arc of curvature of ψ = 37° from 1 to 12 ECAP passes at room temperature following route B_c. To analyze the evolution of the microstructure at increasing ECAP passes, X-ray diffraction and electron backscatter diffraction analyses were carried out. The results revealed two distinct processing regimes, namely (i) from 1 to 5 passes, the microstructure evolved from elongated grains and sub-grains to a rather equiaxed array of ultrafine grains and (ii) from 5 to 12 passes where no change in the morphology and average grain size was noticed. In the overall behavior, the boundary misorientation angle and the fraction of high-angle boundaries increase rapidly up to 5 passes and at a lower rate from 5 to 12 passes. The crystallite size decreased down to about 45 nm with the increase in deformation. The influence of deformation on precipitate evolution in the Al–Mg–Si alloy was also studied by differential scanning calorimetry. A significant decrease in the peak temperature associated to the 50% of recrystallization was observed at increasing ECAP passes.     

Flow characteristics of continuous shear drawing of high carbon steel

Equal channel angular drawing (ECAD) is a method to obtain the material with large plastic deformation in a continuous way. While flow instability tends to occur at the exit channel during the ECAD, the shear drawing (SD) process might be an alternative technique that secures stable flow and continuous process at the same time. The aim of the present work is to develop the SD process, which prevents flow instability of the ECAD and imposes a high plastic deformation on the material. For this purpose, the multi-pass SD process consisting of the die intersection angle of 150° was designed by the finite element analysis. For verification of the designed process, experiments were carried out with commercially available high carbon steel. Experimental results showed that the newly designed SD process improved flow stability and roundness of the specimens compared to the conventional ECAD. Compression and hardness tests were made to investigate mechanical property of the specimen. Scanning electron microscopy was employed to check changes of the microstructure. The results of SEM indicated that the original cementite lamellae were fragmented into short and distorted segments. Additional numerical study was carried out to investigate flow characteristics and distribution of the effective strain with varied die intersecting angles. According to the present investigation it was found out that the effective strain value and flow instability increased by decreasing the intersecting angle.     

An analytical solution of the ECAE process of bi-layer strip using a Bezier type streamline

Co-extrusion of strips of different strength and ductility is a process in the production of bimetal rods of desirable physical and mechanical properties. Equal channel angular extrusion (ECAE) is an innovative process for applying severe plastic deformation to materials. The present study is concerned with the ECAE of different bi-layer strips. Developing a kinematically admissible velocity field using a Bezier-type streamline is the aim of present research. In this analysis, using the mentioned velocity field and the upper bound theorem, the extrusion force as well as the strain distribution in the deformation zone of the ECAE process are predicted. The solution takes into account the die profile, friction conditions, strength, arrangement and thickness ratio of the layer materials. Experimental results of ECAE of aluminum/copper and aluminum/mild steel bi-layer strips showed a good agreement with the predicted results.

     

The effect of equal channel angular pressing on the mechanical and magnetic properties of 09Γ2C steel

The physical and mechanical properties of 09Γ2C steel that was subjected to strengthening by intense plastic deformation using the method of equal channel angular pressing (ECAP) are studied. An unambiguous interrelationship between the magnetic (coercive force, maximal permeability, Barkhausen magnetic noise parameters) and mechanical (rupture limit, conditional yield strength, relative elongation and narrowing upon damaging) characteristics of 09Γ2C steel, which was strengthened using ECAP following different technological regimes, is demonstrated. Therefore, it is possible to estimate the strength and plasticity characteristics of the analyzed material based on the measurement of its magnetic parameters. It has been revealed that under conditions of uniaxial tension in the range from 0 to (0.2–0.6) of the conditional yield strength (depending on the ECAP regime), it is possible to diagnose changes in the stressed state of items that are made of 09Γ2C steel that is hardened in accordance with the ECAP technique using magnetic structuroscopy methods.     

等径角挤压工艺研究及其新进展

概述了等径角挤压（ECAP）工艺的基本原理及通道交角角度、挤压方式、挤压温度、挤压速度等影响因素,介绍了ECAP法为了适应工业化生产新发展出来的连续等径角挤压方法,如旋转模具ECAP技术,多级连续ECAP法、板材连续剪切变形法、ECAP—Conform新技术等,并对今后ECAP的发展方向进行了展望。     

铝-钛-硼中间合金在等径角挤压过程中的变形行为

采用等径角挤压(ECAP)技术对铝-钛-硼中间合金进行了室温挤压试验,用高温光学显微镜、扫描电镜、硬度计等分析了ECAP对合金中第二相粒子分布形态、尺寸及显微硬度的影响.结果表明:ECAP能显著改善合金中第二相粒子的分布形态,细化其尺寸;用试样绕其纵轴旋转9°.、方向不变的加工路径(Bc),经过8道次挤压后,第二相粒子由原来的散乱分布变成较为均匀分布,由原长约20μm、宽约10μm的块状粒子细化为5μm左右的小颗粒;挤压1道次后,材料硬度增加最为明显,4道次后硬度增加趋势变缓.     

等通道转角挤压技术及其工程应用研究

等通道转角挤压技术（ECAP）是一种目前最有工程应用潜力的大塑性变形（SPD）细晶材料制备技术，具有材料组织细化效果好、加工材料尺寸大等优点。阐述了ECAP处理对材料性能的影响，主要包括材料强韧性能的提高、超塑性的获得以及材料疲劳性能和功能特性的改善。在此基础上，探讨了近年来ECAP技术在工业化应用方面的研究进展，如各种大尺寸材料加工的试验研究、连续化生产和提高加工效率的解决方案等，同时指出了目前研究中存在的不足之处和需要解决的主要问题。     

新型等通道转角挤压模具优化设计

设计出一种新型的等通道转角挤压模具,推导出该模具下工件变形等效应变值的理论表达式,并应用3D有限元分析技术,分析了模具转角区的外倒角半径R和内倒角半径r的变化对工件变形的变形行为、应变分布和挤压所需的最大栽荷的影响.研究结果表明,R和r的增大都可以减小变形死区面积,但r影响更显著;R的增大将导致最大载荷的迅速减小,而r对其影响甚微.     

A computational study of die geometry and processing conditions effects on equal channel angular extrusion of a polymer

Equal channel angular extrusion (ECAE) is an efficient process to obtain enhanced microstructures via super-plastic deformation. In view of its optimisation, it is of prime importance to assess the relationships between processing conditions and material flow. More precisely, detailed knowledge of the plastic strain distribution in the extruded material in relation to the ECAE processing variables is required. The key parameters of the ECAE process are primarily die geometry, ram speed, extrusion temperature, use of back-pressure, number of extrusion sequences and processing route (e.g. rotation of the sample between successive passes). A numerical investigation was achieved to check out the influence of these parameters on the homogeneity of plastic strain distribution in the case of a conventional thermoplastic polymer. Material parameters of a phenomenological elastic viscoplastic model were deduced from compressive deformation tests at different temperatures and strain rates on high-density polyethylene (HDPE). Recommendations on tool geometry and processing conditions can then be provided, according to the numerical results.It was found that optimum ECAE die geometry is strongly material dependent. The application of a back-pressure significantly contributes to reduce the corner gap and consequently promotes the homogeneity of the plastic strain field. A slight sensitivity of plastic strain to ram speed and friction conditions was pointed out. The extrusion temperature strongly influences the magnitude of the plastic strain and has a slight effect on its homogeneity. The number of passes has a significant effect on the magnitude of the plastic strain but has a negligible influence beyond a certain temperature. The extruded material reaches a stationary strain state after few passes. The homogeneity of the plastic strain field is strongly affected by the processing route.     

连续 ECAP 大应变的数值模拟研究

基于刚塑性有限元理论,采用有限元软件DEFORM-3D对5052铝合金连续ECAP(Equal Channel Angular Pressing)大应变成形过程进行了三维数值模拟研究,研究了工件的变形过程以及应变均匀性,温度的分布规律。模拟结果表明,金属变形剧烈部位主要集中模具的拐角区域,该区域的等效应变呈层状分布,而且变化梯度较大并且温度最高。模拟结果对实际生产具有很好的指导作用。