Abstract
The rigid plastic finite element method was used to simulate the repetitive upsetting extrusion (RUE) process of an AZ61 magnesium alloy. Flow nets, field variables and the influence of initial blank temperature and RUE passes on the RUE process were analysed systematically. The results showed that large accumulated strain induced by multi-pass operation could be obtained by RUE process. The applied load versus displacement curves were obtained by RUE process test and the forming principle was revealed. Microstructure evolution during RUE process was demonstrated by microstructure observation, which revealed that the RUE strain induced process has a pronounced effect on grain refinement. Under the conditions of 340°C and 1 mm s−1, the initial cast structure with average grain size of 95 μm evolved to fine and uniform DRX grains with average grain size of 6·9 μm after three RUE passes.
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