Finite element analysis of the Non-Equal Channel Angular Pressing (NECAP) with different die geometries

The Non Equal Channel Angular Pressing is one of the promising severe plastic deformation techniques which is used to produce ultra-fine grained and nanostructured materials. In the present investigation, the deformation behavior of Al1100 alloy during non-equal channel angular pressing was studied using two dimensional finite element simulation. Results showed when the ratio of the width of output to input channel is higher than 0.7, the corner gap is formed in the outer side of the intersecting area of two channels and the amount of plastic strain decreases in the lower part of the sample. In contrast, when the amount of this ratio is lower than 0.7, the dead metal zone is formed in the outer region of the intersecting area and the amount of strain is increased in the lower side of sample. It is also observed that the uniformity of the applied plastic strain is decreased with the formation of dead metal zone. In addition, the amount of damage factor is increased with increasing the ratio of the width of output to input channel and the region with higher amounts of damage factor is shifted from the lower side to the middle region of deformed sample. Finally, the results of FEM simulation showed that the amount of pressing force is decreased with increasing the width of output channel.