Abstract
Severe plastic deformation techniques can be used to produce refined grain of metals and alloys. Repetitive corrugation and straightening (RCS) is a severe plastic deformation technique where bending and straightening of a workpiece is repeatedly done with no change in its cross section geometry, with potential to be a continuous manufacturing process. This study aims to analyse the effect of corrugation die designs in repetitive corrugation and straightening of a magnesium alloy using finite element method. The die designs were toothed-gear, saw edged, and sinusoidal. AZ91 magnesium alloy was the workpiece material. The magnitude and distribution of the plastic strain on the magnesium alloy workpiece was analysed. The results were that the highest equivalent plastic strain of 1.18 was produced by saw edged die, but the most uniform strain distribution was produced by sinusoidal die.
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