Study of channel angle influence on material flow and strain inhomogeneity in equal channel angular pressing using 3D finite element simulation

Equal channel angular pressing (ECAP) is currently being widely investigated because of its potential to produce ultra-fine grained microstructures in metals and alloys. A sound knowledge of the plastic deformation and strain distribution is necessary for understanding the relationships between strain inhomogeneity and geometry of die. Considerable research has been reported on finite element analysis of this process, assuming 2D plane strain condition. The 2D models are not suitable due to the component geometry, especially for workpiece with cylindrical cross-section. In the present work 3D simulation of ECAP process was carried out, using ABAQUS/Standard software, for different channel angles for a strain hardening aluminium alloy (AA6101). Strain inhomogeneity is presented and discussed for all cases. Pattern of variation of strain along some selected radial lines in steady-state zone is presented.