Analytical and Experimental Investigation of Process Loads on Incremental Severe Plastic Deformation

From the processing point of view, friction is a major problem in the severe plastic deformation (SPD) using equal channel angular pressing (ECAP) process. Incremental ECAP can be used in order to optimize frictional effects during SPD. A new incremental ECAP has been proposed recently. This new process called as equal channel angular swaging (ECAS) combines the conventional ECAP and the incremental bulk metal forming method rotary swaging. ECAS tool system consists of two dies with an angled channel that contains two shear zones. During ECAS process, two forming tool halves, which are concentrically arranged around the workpiece, perform high frequency radial movements with short strokes, while samples are pushed through these. The oscillation direction nearly coincides with the shearing direction in the workpiece. The most important advantages in comparison to conventional ECAP are a significant reduction in the forces in material feeding direction plus the potential to be extended to continuous processing. In the current study, the mechanics of the ECAS process is investigated using slip line field approach. An analytical model is developed to predict process loads. The proposed model is validated using experiments and FE simulations. (paper)