SIMULATION OF THE SEVERE PLASTIC DEFORMATION OF AISI 1045 CARBON STEEL DURING EQUAL CHANNEL ANGULAR PRESSING (ECAP)

ABSTRACT: Equal Channel Angular Pressing (ECAP) is a high-strain plastic deformation process used to enhance the mechanical properties of materials, particularly metals, by subjecting them to severe deformation. This process is widely employed to refine the microstructure of materials, thereby improving their performance. The objective of this study is to investigate the influence of two critical process parameters the channel angle (Φ) and the friction coefficient (μ) between the workpiece and the die channel on the distribution of plastic deformations and deformation inhomogeneity during a single pass of ECAP. This investigation is conducted using the Finite Element simulation program ABAQUS. A 3D finite element model incorporating varying channel angles (Φ) and friction coefficients (μ) is developed for this purpose. For each case study, the distribution and inhomogeneity of the equivalent plastic deformation (PEEQ), as well as its evolution over time, are analyzed. The results demonstrate that plastic deformations increase as the channel angle decreases and the friction coefficient increases. Additionally, the findings reveal that deformation inhomogeneity can be minimized by carefully selecting optimal process parameters. The results exhibit a high degree of consistency with those reported in the literature, confirming that the proposed 3D finite element model accurately simulates the distribution of plastic deformations during the ECAP process.