Finite Element Analysis of ECAP, TCAP, RUE and CGP Processes

Abstract

A finite element method was applied to study the various severe plastic deformation processes like, Equal Channel Angular Pressing (ECAP), Tubular Channel Angular Pressing (TCAP), Repetitive Upsetting and Extrusion (RUE) and Constrained Groove Pressing (CGP), considering aluminum AA-390 alloy as specimen material for all these processes. FEA simulation was carried out using AFDEX simulation tool. Effect of the various ECAP process parameters like, die corner angle, channel angle, and the coefficient of friction were analyzed. The die corner angles were divided into 2 equal parts for increasing the effectiveness of ECAP process, thereby increasing the channel number from 2 to 3 and further, their influence on ECAP process was investigated. A 3D simulation of TCAP was carried out for die shapes like triangular and trapezoidal, and variation of the generated stress and strain was plotted. In CGP, four cycle operation was carried out; wherein each cycle is composed of corrugating the specimen and subsequent straightening to original dimension. During RUE process, a maximum effective stress of 683.1 MPa was induced in the specimen after processing it for four complete cycles of RUE process; whereas the maximum strain induced during the same condition was 3.715.