Upper-Bound Analysis for Equal Channel Angular Pressing (ECAP) with an Intersecting Channel Angle of 120°

Abstract

The exact calculations of the stress and strain distributions based on the controlling equations for a forming process with large deformation are often difficult. To circumvent such difficulties, some analytical methods such upper-bound analysis and slip-line field theory have been established by making a number of simplifying assumptions regarding the material properties and deformation modes. In this work an analytical model based on the upper-bound theory was successfully developed to predict material flow pattern and maximum process loads for an Equal Channel Angular Pressing (ECAP) die with circular cross-section and an intersecting channel angle of 120°. Based on the model, the power dissipated on all frictional and velocity discontinuity surfaces were determined and optimized in order predict the maximum process force as function of the channel geometry and the material plastic behavior. To validate the developed model, the ECAP die were produced and used to determine experimental load-displacement curves of AA6061-T6 specimens with different lengths. A good correlation between theoretical and experimental results was observed. In addition, the constant friction factor demonstrated to have a strong effect on the relative extrusion pressure.

Keywords:
severe plastic deformation; equal channel angular pressing; upper-bound analysis; constant friction factor