ISSN: 1003-6326
CN: 43-1239/TG

Vol. 27    No. 6    June 2017

3D FEM simulations and experimental validation of plastic deformation of pure aluminum deformed by ECAP and combination of ECAP and direct extrusion
Mohamed Ibrahim Abd EL AAL1,2
(1. Mechanical engineering Department College of Engineering, Prince Sattam Bin Abdulaziz University, Wadi Addawasir, Kingdom of Saudi Arabia;
2. Mechanical Design & Production Department, Faculty of Engineering, Zagazig University, Zagazig, Egypt
Abstract: Rigid-viscoplastic 3D finite element simulations (3D FEM) of the equal channel angular pressing (ECAP), the combination of ECAP + extrusion with different extrusion ratios, and direct extrusion of pure aluminum were performed and analyzed. The 3D FEM simulations were carried out to investigate the load-displacement behavior, the plastic deformation characteristics and the effective plastic strain homogeneity of Al-1080 deformed by different forming processes. The simulation results were validated by microstructure observations, microhardness distribution maps and the correlation between the effective plastic strain and the microhardness values. The 3D FEM simulations were performed successfully with a good agreement with the experimental results. The load-displacement curves and the peak load values of the 3D FEM simulations and the experimental results were close from each other. The microhardness distribution maps were in a good conformity with the effective plastic strain contours and verifying the 3D FEM simulations results. The ECAP workpiece has a higher degree of deformation homogeneity than the other deformation processes. The microhardness values were calculated based on the average effective plastic strain. The predicted microhardness values fitted the experimental results well. The microstructure observations in the longitudinal and transverse directions support the 3D FEM effective plastic strain and microhardness distributions result in different forming processes.
Key words: equal channel angular pressing (ECAP); extrusion; finite element method (FEM); microhardness; deformation homogeneity; microstructure
Superintended by The China Association for Science and Technology (CAST)
Sponsored by The Nonferrous Metals Society of China (NFSOC)
Managed by Central South University (CSU)