Deformation analysis of Al Alloy AA2024 through equal channel angular pressing for aircraft structures

Abstract

Equal Channel Angular Pressing (ECAP) is one of the most innovative Severe Plastic Deformation (SPD) methods used for grain refinement of materials up to ultra-fined or Nano structured level which leads to superior mechanical properties. Computer simulation is one of the best alternative of actual ECAP deformation to know the influence of each processing parameters on end results. In the present work, AA2024 alloys is used, which is a demanding material in aircraft structure and automotive applications. To understand the process/die design parameter, 3D FEM simulation is done on ECAP process using DEFORM-3D software. Simulation was done on different channel angles such as 90º, 105º, 120º and 135º and corner angles such as 0º, 10º, 20º and 30º. The ECAP process was simulated for a single ECAP pass. The results concern to the extrusion load, developed stresses, effectivestrain and temperature variation on the processed material were noted obtained. From the observed results, it was found that the minimum channel angle produces the maximum temperature profile on the material, develop maximum stress and strain at deformation zone. Additionally, the outcome acquired by such computational technique illustrate that the shear strain decrease with increase in channel and corner angle.