Finite Element Analysis of Plastic Strain Distribution in Multipass ECAE Process of High Density Polyethylene

Equal channel angular extrusion (ECAE) is a relatively novel forming process to modify microstructure via severe plastic deformation without modification of the sample cross section. In this study, an optimized design of die geometry is presented, which improves homogeneity of the plastic deformation and decreases the pressing force required for extrusion. Then, a typical semicrystalline polymer (high density polyethylene) was subjected to multipass ECAE using two different processing routes: route A where the sample orientation is kept constant between passes and route C where the sample is rotated by 180 deg. Compression tests at room temperature and under different strain rates were used to identify the material parameters of a phenomenological elastic-viscoplastic model. Two-dimensional finite element analysis of ECAE process was carried out, thus allowing to check out the homogeneity of the plastic strain distribution. The effects of die geometry, number of passes, processing route, and friction coefficient on the plastic strain distribution were studied. The simulations were performed for three channel angles (i.e., 90 deg, 120 deg, and 135 deg), considering different corner angles. According to simulation results, recommendations on the angular extrusion of the polymer are provided for improving die and process performance.