Numerical and physical modelling of plastic deformation in 2-turn equal channel angular extrusion

A new process of 2-turn equal channel angular extrusion (ECAE) was simulated by finite element method with a view to providing an insight into the mechanics of the process. The stress results obtained gave indication of expected forces and tool contact stresses. Plastic flow sensitivity analysis, with respect to geometrical features of the die, enabled process and tool design guidelines to be formulated. Two methods of increasing productivity of 2-turn ECAE were presented and simulated using finite element method. Physical modelling experiments with wax billets validated the results of numerical simulation and also gave indication of possible problems with the real process.