Abstract
The manufacturing of a functional hollow mechanical element or ring of the AA5083 alloy previously equal channel angular extrusion (ECAE) processed, which presents a submicrometric microstructure, is dealt with. For this purpose, the design of two isothermal forging dies (preform and final shape) is carried out using the design of experiments (DOE) methodology. Moreover, after manufacturing the dies and carrying out tests so as to achieve real rings, the mechanical properties of these rings are analysed as well as their microstructure. Furthermore, a comparison between the different forged rings is made from ECAE-processed material subjected to different heat treatments, previous to the forging stage. On the other hand, the ring forging process is modelled through the use of finite element simulation in order to improve the die design and to study the force required for the isothermal forging, the damage value, and the strain the material predeformed by ECAE has undergone. With this present research work, it is intended to improve the knowledge about the mechanical properties of nanostructured material and the applicability of this material to industrial processes that allow the manufacturing of functional parts.
Highlights
Severe plastic deformation (SPD) processes constitute a novel alternative for the attainment of material accumulating high values of strain (ε ≫ 1)
The cross-section that can be observed in Figure 2(b) is that employed for the ring die, where, as in the previous case, this has a geometry with fixed values and other variable values that will be analysed by design of experiments (DOE)
The optimal geometrical parameters of the forging dies for manufacturing the rings have been selected by using FEM simulations along with design of experiments
Summary
Severe plastic deformation (SPD) processes constitute a novel alternative for the attainment of material accumulating high values of strain (ε ≫ 1) To this end, over the past few years, there have been a large number of studies dealing with the modification of mechanical properties and microstructure achieved in the material when accumulating this deformation level [1, 2]. The equal channel angular extrusion (ECAE) is a discontinuous SPD process which was firstly developed by Segal in the former Soviet Union [3] This process consists in exerting a compression force to a material through a die with two channels of, approximately, the same cross-section which intersect at an angle between 90∘ and 120∘. At the beginning of the crack, there is a strong interaction between dislocation emission and crack propagation, which is mainly influenced by the microstructure [8]
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