Deformation behavior of consecutive workpieces in equal channel angular pressing of solid dies

In this study, consecutive workpiece equal channel angular pressing (ECAP) in solid-dies, where the second workpiece is successively deformed without splitting and reassembling the die after the first workpiece processing, is employed to reduce the processing time in ECAP. The plastic deformation behavior of the two workpieces was investigated in terms of strain homogeneity, load, and defects using the finite element method (FEM). The experimental deformations of the consecutive workpiece during ECAP were compared with the FEM results, and it was found that the deformation was more heterogeneous in the second workpiece when compared with the first workpiece. The primary reason behind these findings is that the deformed geometry of the second workpiece was a back slant type and the first deformed workpiece provided back pressure to the second workpiece. Furthermore, the folding defect was less pronounced in the second workpiece because of the back slant head shape. Despite the less homogeneity in strain, the ECAP of the consecutive workpieces is an effective process for less defective materials and increases process efficiency.