Investigation into equal channel angular extrusion process of billet with internal defects

The shear plastic deformation behavior of a material during equal channel angular (ECA) extrusion is governed primarily by the die geometry, the material properties, and the process conditions. This study uses the commercial DEFORM™ 2D (two-dimensional) rigid-plastic finite element code to investigate the plastic deformation behavior of materials with internal defective voids during 1- and 2-turn ECA extrusion processing. The present simulations investigate the damage factor distributions, the total velocity distributions, the rotation angle distributions, the void dimension, and the stress–strain distributions around the defective voids under various extrusion conditions. The mesh element increase of the billet mesh in the 2-turn ECA extrusion process is also investigated. The present numerical results provide valuable insights into the shear plastic deformation behavior of materials containing defective voids in the ECA extrusion process.