Integrated 3D finite element modeling and experimental assessment of severe plastic deformation in pure aluminum using multiple techniques

Abstract 3D-FEM three-dimensional finite element simulations of equal-channel angular pressing (ECAP) and cyclic extrusion compression (CEC) of Al were performed to predict load-displacement behavior, strain distribution, and damage factor, and confirm them experimentally. The deformation mechanism in each process affects the load-displacement behavior. The load-displacement curves of the ECAP and CEC processes were predicted with a maximum deviation of 4.3% from the experimental loads. The complexity of CEC processing revealed a higher peak load by 265.4% than ECAP. The strain distribution indicates an increase from the bottom to the top and from the center to the surface after one pass and cycle of ECAP and CEC. However, the deformation homogeneity of both processes increases with further processing, resulting in higher homogeneity of ECAPed samples. The FEM average strain values after the ECAP and CEC were deviated by 2.3–9.6% from the theoretical equations. The microhardness distribution and homogeneity index effectively confirm the strain results. The average damage factor of the CECed samples was higher by 21.8–57.3% than that of the ECAP, confirmed through the heavily deformed shear bands observed after 10 cycles.