Finite element analysis of die angle at constant offset length in two-turn ECAP

Severe plastic deformation (SPD) is the process used to produce smaller grain in the range of 1-pm. These materials have been classified as equiaxed ultrafine grain (UFG) metals. These metals are characterised by high defect density and improved mechanical properties which make them suitable for advanced structural applications. From all available SPD techniques, two turn incremental equal channel angular pressing (ECAP), S-shape channel discussed in this paper to double the effective strain in single press. Analysis of ECAP technique by changing die geometry and process parameter helps to produce defect free UFG metals. ECAP channel continuously pressed a very long billet in which repetitions accumulate large plastic strain. Two turn ECAP is useful to increase the productivity. However, any changes in channel angle, corner angle as well as offset length are cause for variation in mechanical properties of metals. In order to check the die suitability of two-turn ECAP with variation of die angle a finite element analysis (FEA) simulation is carried out and the suitable tool geometry with process kinematics are established. ECAP channels at two different channel angles are used to study the flow behaviour of metal through 15mm offset length. The mode of material flow is the same as in the well-established classical L-shape ECAP process following route C pass, while continuous character and improved productivity suggest that new S-shape ECAP process might be suitable for grain refinement of metals as well as minimization of deformation load on an industrial scale. (paper)