3D FEM simulations for the homogeneity of plastic deformation in aluminum alloy HS6061-T6 during ECAP

The knowledge of deformation behavior and strain homogeneity is essential to design a sound ECAP die. Thus, the current study dealt with the influence of channel angle on the deformation behavior and strain homogeneity in ECAP by conducting finite element simulations with COSMOS for a range of channel angles along with the consideration of strain hardening of the material and friction. Complicated and smooth deformation behaviors are observed with φ<110° and φ≥110°, respectively. Effective strain variation across the width at the centre of the sample showed that strain homogeneity is greater with φ=110° compared to the other channel angles. The effective plastic strain index of inhomogeneity decreased with the number of ECAP passes. From the experimental and FEM results, φ=110° and 130° was found to give higher homogeneity than φ=70° and 90°.