Abstract
In the current study, the effect of friction coefficient on strain distribution and deformation was investigated with the computer simulation providing a better understanding of the material flow mechanism and deformation behavior in the ECAP. The 10×10 mm and 50 mm-long rectangular billet was used as the geometry of aluminum material. The geometry of dies is 105° channel angle, 0 mm inner fillet radius, and 5 mm outer fillet radius. The dies were modeled as rigid bodies, and the specimen was assumed as a bilinear hardening model. The effect of friction was investigated with the three-level variation coefficient of friction (0.01; 0.025 and 0.05). Based on the result, it can be shown that the friction affects the strain distribution condition. The friction of 0.05 produced more uniform strain distribution, better homogeneity, and smaller corner gap. The experimental study of modeling results was done with MoS2 lubricant while the strain distribution was verified by the microhardness test. The microhardness distribution test result was similar to strain distribution from modeling.
Highlights
equal channel angular pressing (ECAP) (Equal Channel Angular Pressing) is an innovative process to obtain severe plastic deformation (SPD) and superior mechanical properties through grain refining technique [1]
Optimal die design and homogenous distribution of shear stress are the objectives of the ECAP process product
The homogeneity index is determined homogeneity. This decision is supported that 0.05 friction by measuring the strain that occurs on the workpiece in the produces a smaller corner gap and more uniform strain as ECAP process
Summary
ECAP (Equal Channel Angular Pressing) is an innovative process to obtain severe plastic deformation (SPD) and superior mechanical properties through grain refining technique [1]. Optimal die design and homogenous distribution of shear stress are the objectives of the ECAP process product. Modeling from the previous study resulted in dies with specific parameters, the effect of friction on the dies has not been further investigated. Computer simulations evolved as a favorite tool to predict process parameters to obtain optimal dies design. Initial prediction of process parameters and dies design can be constructed to reduce the experimental trial and errors, and cost and time of production process can be minimized. The computer simulation on the ECAP process was investigated by using a 2-dimensional model with the plane strain assumption [6]. Three-dimensional modeling to determine the effect of friction between the billet with the entire surface of dies was performed. The ECAP process is simulated in 3 dimensions to provide more information on the analysis of ECAP process results
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