Optimal tool angles for equal channel angular extrusion of strain hardening materials by finite element analysis

Equal channel angular extrusion (ECAE) is a novel deformation process capable of imparting a large amount of plastic strain to bulk material through the application of uniform simple shear. ECAE die geometry, material properties and process conditions influence the shear deformation behavior during extrusion that in turn governs the microstructure and mechanical properties of the extruded materials. Finite element analysis, the most appropriate technique was used to analyze the deformation behavior of extruded materials without neglecting important and realistic factors like strain hardening behavior of the material, frictional conditions and speed of the process. In this study the deformation behavior of material, dead zone/corner gap formation and strain homogeneity achieved in the samples during ECAE were studied by using commercial finite element code Abaqus/Explicit. The influence of tool angles, strain hardening behavior of material and friction between the billet and die was considered for simulations. Results showed that the optimal strain homogeneity in the sample with lower dead zone formation, without involving any detrimental effects, can be achieved with channel angle of 90° and outer corner angle of 10°.