Study of Multi Pass Equal Channel Angular Pressing Using 3D Finite Element Analysis

Equal Channel Angular Pressing (ECAP) has emerged as most prominent Severe Plastic Deformation (SPD) technique used to produce an ultrafine grained ((JFG) structure in metals in order to improve their mechanical and physical properties. In this work Finite Element modeling of ECAP is attempted in FORGE 2007 environment. Four passes of the ECAP process of lOmm square shaped AL 6061 billet were carried out for routes A, B-A and C for different channel angles and values of coefficient of friction to investigate their influence on the billet. The models were developed assuming a range of friction conditions at the billet-die contact region considering eight distinct friction coefficient (mu) values of 0.0, 0.10, 0.15, 0.20, 0.25, 0.30, 035 and 0.40, respectively. The simulations are carried out using three distinct situations of die channel angles (Phi), 90 degrees, 105 degrees, and 120 degrees respectively. Route 'B-A' emerged as a better method among the three routes studied and 90 degrees channel angle appeared to be optimal in terms of producing high equivalent strain.