Shape Effect of Angular Die External Wall on Strain Unevenness during Equal Channel Angular Extrusion

The principal objective of the present article is to take into account the effect of deformation zone geometry on the deformation unevenness of material plastic flow in the Equal Channel Angular Extrusion (ECAE) of metals through the use of 2D Finite-Element Simulation. This approach allows us to analyze plastic material flow through the proposed generalized Iwahashi angular die with a variable external wall at the channel intersection zone. A varied set of quadratic curves has been used to define the possible external wall of the contact surface zone. The proposed approach allows us to extend ideas concerning the influence of the angular die deformation zone external wall on the energy-power parameters of the equal channel material flow. The results indicate that the preferred choice is to introduce the external die wall in the form of a hyperbola, which allows the achievement of high strain intensity 0.692 … 0.792, low strain unevenness 0.167 … 0.310, and low material waste 0.016 … 0.047 during one pass of the processed metal through the generalized angular die with a channel intersection angle of 90°.