Effect of 2θ-Punch Shape on Material Waste during ECAE through a 2θ-Die

Abstract

This article mainly focusses on the improvement of metal forming die tooling for equal channel angular extrusion (ECAE) processes through nonrectangular 2θ-dies of classical Segal geometry. The technological appropriateness of workpiece deformation through 2θ-dies using inclined oblique 2θ-punches has been evaluated with the introduction of physical simulation techniques. It has been shown experimentally that for the best efficiency, the geometric condition required for the taper angle of the inclined oblique punch is equal to the 2θ angle between the inlet and outlet channels of the angular die. Physical simulation shows that the application of an oblique inclined 2θ-punch provides workpiece dead zone area downsizing and macroscopic rotation reduction during ECAE. The use of numerical finite element modeling simulation also confirms the usefulness of the oblique inclined 2θ-punch for increase of the utilization ratio and decrease of the maximum deformation and unevenness of deformation distribution.