International Journal of Mechanical Engineering and Computer Applications,

Vol 2, Issue 2, March- April 2014, ISSN 2320-6349

Modelling and analysis on deformation behaviour of AA6061

through equal channel angular extrusion (ECAE) die
Raghuraman Sa, Deepak Mb, Muthukumarasamy@Sathish Kumarb, Vignesh Bb
a
Professor,School of Mechanical Engineering, SASTRA University, Thanjavur 613401, India
b
UG Scholars Mechatronics, School of Mechanical Engineering, SASTRA University, Thanjavur 613401, India

Abstract- Equal Channel Angular Extrusion (ECAE) is

one of the methods of severe plastic deformation (SPD)
generally used for effective grain refinement of
materials, consolidation of powder materials and
property enhancements of materials. The channel angle
in ECAE die is having significant influence to introduce
strain on the material during pressing. The imparted
strain and the loading condition on the material
increases while the channel angle decreases. This paper
aims to formulate an optimal ECAE condition for
AA6061-T6 Aluminum Alloy through modeling and
analysis using DEForm software.

Keywords: Severe plastic deformation, Grain

refinement, Channel angle

1.Introduction
Severe plastic deformation (SPD) is a term coined to
promote the profound changes in the microstructure of the
metals and alloys. The effect of SPD is that it leads to
noticeable grain size reduction subsequently increasing the
strength. The processed material tends to show ultra-fine
grained materials. Light materials with greater strength are
the present requisites for aerospace and auto industries.
Grain refinement or inoculation provides refined grains
suitable for cryogenic temperature environments. ECAE is
one of the SPD practice to impart severe strain by simple
shear achieved by passing the material through a ECAE die
with reduction in the cross sectional area of the sample and
inducing homogeneity[1]. The current study deals with the
influence of channel angle on deformation behavior for
AA6061-T6 through analysis in DEForm for different
channel angles of 90, 110 and 120 using a Mechanical
Hammer for imparting load. The process largely relies
upon critical process parameters like Channel angle (2),
Corner angle (), friction considered and strain hardening
effect of the material being processed.
Fig 1. ECAE die showing Channel angle
The effect of channel angle and corner angle is given by
segal et al., [2] as
= + + +
(1)
From the equation (1),it is observed that the imparted strain
in the specimen increases with decrease in channel angle.
Greater strain homogeneity is obtained in an angle closer to
angle 90 compared to all other channel angle while
keeping the corner angle as 90[3]. It is experimentally
easier to press billets when using dies with angles that are
larger than 90[4]. For 90 the load required is relatively
lesser than 60[5]. Although 90 channel angle dies are
effective, the work piece can be pressed using the dies with
channel angles greater than 90 (Valiev et al.) [6]. Thus,
the scope of study of this project will only be focused on
channel angles 90, 110, and 120. The effect of corner
angleis neglected in the strain hardening materials as the
deformation in the die design was predicted to be almost
independent of the die corner angle (Yoon et al.) [7].For
effective study of process parameters an experimental setup
of the diehas been created in pro-E and subsequent analysis
has been carried out in DEForm software. The simulation

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 International Journal of Mechanical Engineering and Computer Applications,
Vol 2, Issue 2, March- April 2014, ISSN 2320-6349
process consumes lesser time and helps in effective
analysis to estimate the credibility of the die. Hence this
method proves to be a better way in studying the effect of
process parameters.

2. Experimental procedure

In the ECAE die model, channel angle (intersection of

two channels) is 110, inner radius(r) is 0.5mm and outer
radii(R) is 10mm, length of the inner channel is 130mm,
length of the outer channel is 160mm and the diameter of
the sample is 15mm. The die for ECAE is designed in pro-
E with three different channel angles i.e. 90, 110 and
120 as shown below. The die models are assumed to be
rigid and homogeneous. The specimen material is assigned
as Aluminum alloy AA6061-T6, Cold and is assumed to be
isotropic, homogeneous and plastic. Frictionless condition
is assumed. The forming methodology is cold forming at a
predefined temperature of 35C for the top die, billet and
bottom die.

3. Die Design for Various channel angles:

Fig 3: 3D models of the die design

Assembled die for 110

The boundary conditions assumed for the analysis are

The body of the ECAE die is considered as
rigid and the punch is allowed to move only in
the channel direction which is in contact with
the top surface of the specimen.
The ram moves only in the channel angle
direction and all the nodes of the top die were
given displacement. The simulation results are
obtained from DEFORM 3D and graphs were
plotted. The parameters to be analysed and
discussed from the results are effective strain,
effective stress and maximum load required for
various channel angles.
Fig 2: 2D models of the die design

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 International Journal of Mechanical Engineering and Computer Applications,
Vol 2, Issue 2, March- April 2014, ISSN 2320-6349

4. Results and Discussion

a. For 90:

From the graph it is inferred that the load distribution for

90 is higher and the effective strain developed due to the
induced stress during ECAE is large (204mm). The force
requirement is high to facilitate the displacement.
For 120:
From the graph it is inferred that the load distribution for
120 decreases drastically and the effective strain
developed due to the induced stress during ECAE is less
(14.1mm). The force requirement is minimal to facilitate
the displacement.

For110:

From the graph it is inferred that the load distribution for

110 decreases and the effective strain developed due to the
induced stress during ECAE is moderate(17.4mm). The
force requirement is less to facilitate the displacement.

Snapshots of analysis of strain, stress& velocity:

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 International Journal of Mechanical Engineering and Computer Applications,
Vol 2, Issue 2, March- April 2014, ISSN 2320-6349

Parameters Change in Loading Imparted

parameter Condition Strain It is thus evident from the above graph that the load
distribution decreases with the increase in the channel
angles. For the angle 90 the max load is obtained at
Channel Increases Decreases Decreases
18.3e+4N, for 110 it is obtained at 2.86e+4N and for 120
Angle
it is obtained at 0.226e+4N.Hence it can be easily inferred
that with the increase of channel angle, the load distribution
External Increases Decreases Decreases in the die decreases thus allowing easier flow and lesser
Radius R strain.

5.Conclusions
Internal Increases Increases Increases
Radius r Process is finished in single passcompared to
multiple passing routes in ECAP.
Better grain refinement is achieved because of
ECAP followed by extrusion.
The loading conditions decrease with increase of
channel angles.
The flow rate is smoother as the angle increases.
More effective strain hardening is observed in
90 channel angle, moderate in 110 and less in
120; hence keeping moderate effective strain
hardening effect and smoother flow of the billet
110 die is preferred.
Requirement of force decreases with the increase
of the channel angle, thus facilitating easy
displacement.
The imparted strain decreases with the increase
of the channel angle. From the results obtained,
204mm strain max is obtained for 90, 17.4mm
for 110 and 14.1mm for 120.

Acknowledgement

The authors thank the Vice-Chancellor of SASTRA

University for allowing us to pursue our project in the
School of Mechanical Engineering of SASTRA University
and at Shanmugha Precision Forging.

References

[1] Valiev RZ, Korznikov AV, Mulyukov RR. Mater

SciEng(1993); A168:141.

[2]V.M. Segal, Materials processing by simple shear,

Material Science Engineering. (1995) A 197: 157164.

[3] A.V. Nagasekhar, Yip Tick-Hon*, H.P.

Seow.Deformation behavior and strain homogeneity in
equal channel angular extrusion/pressing.

[4] R. Ruslan, Z. Valiev , Terence G. Langdon. Principles

Load Time Analysis with respect to channel angle: of equal-channel angular pressing as a processing tool for
grain refinement.

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 International Journal of Mechanical Engineering and Computer Applications,
Vol 2, Issue 2, March- April 2014, ISSN 2320-6349
[5] Langdon TG , Furuno K, Akamatsu H, Oh-ishi K,
Furukawa M, Horita Z,.Acta Mater(2004); 52:2497

[6] Ruslan Z. Valiev,Terence G. Langdon (2006) Principles

of equal-channel angular pressing as a processing tool for
grain refinementProgress in Materials Science (2006): 51;
p 881981

[7] S.C. Yoon, P. Quang, S.I. Hong, H.S. Kim Die design
for homogeneous plastic deformation during equal channel
angular pressing in Journal of Materials Processing
Technology (2007): 187188: p 4650

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