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Table 3.1 Various SPD methods suitable for deforming sheet samples
Process Inventors Year
Degreasing,
wire brushing
Stacking
Roll bonding
Die
F R
x ϕ
Plunger
Sample
Figure 3.3 A schematic drawing of the different stages of the CGP process.
schematically in Fig. 3.3 [3]. In this process, the sample is placed between
a set of asymmetrically upper and lower corrugated dies constrained by a
hollow cylinder. As pressing is performed, the inclined region (hatched
area in Fig. 3.3b) is subjected to pure shear deformation under plane
strain conditions, whereas no deformation is applied at the flat region
(unhatched area). A pressing leads to a shear strain of 1 (effective strain,
εeff 5 0.58) at the deformed zone when the groove angle (θ) is designed
as 45˚. Then, the sample is pressed with a set of flat dies as shown in
Fig. 3.3c. Flat pressing applies a reverse shear deformation to the
deformed region, while the previous undeformed region remains
unchanged. The accumulative equivalent strain of the deformed zone col-
ored in Fig. 3.3c will be doubled and reaches 1.16. The specimen is then
rotated by 180˚ (Fig. 3.3d). This causes the undeformed zone to be
strained by further pressings because of the asymmetry of the grooved
dies. Therefore, the consequent pressings with grooved and flat dies yield
a homogeneous and uniform equivalent strain of 1.16 throughout the
sample. A large amount of equivalent plastic strains can be applied to the
sample without changing its initial dimensions. Thus, an ultrafine grained
structure can be obtained by repeated processing by CGP [3].
Referring to Fig. 3.4 and Eqs. (3.5)(3.9), it can be seen that the
effective strain in a single pressing is equal to 0.58 [24].
t
γ xy 5 γ 5 tanθ 5 5 1 (3.5)
t
118 Severe Plastic Deformation
t
θ
t
rffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
iffi
2 h 2 2 i 4h
εeff 5 εx -εy 1 εy -εz 1 ðεz -εx Þ 1 εxy 1 εyz 1 εzx (3.6) 2 2 2 2
9 3
γxy γ
εxy 5 5 (3.7)
2 2
sffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
2
4 γ=2 γ
ð3:6Þ; ð3:7Þ; ð3:8Þ.εeff 5 5 pffiffiffi .Uεeff 5 0:58 (3.9)
3 3
The plastic strain distributions at the end of one pass show an inho-
mogeneous distribution. The strain at the central region of the sheet
thickness is greater than that of the surface [25] due to the influence of
friction. Controlling the die parameters needs to be designed carefully. At
the larger groove angles, pressing at high cycles of CGP leads to the for-
mation of cracks at the corner of the groove, resulting in a severe stress
concentration on the metal [26]. The CGP method can be regarded as a
discontinuous and time-consuming process [27].
In CGP, the sheet specimen is tightly constrained between the lower
and upper dies. Thus, when the dies press the sheet, the sheet can move
neither in the longitudinal direction nor in the transverse direction.
When processing via unconstrained groove pressing or simply groove
pressing (GP), there is no constraint, and the sample moves freely along
the longitudinal and transverse directions as shown in Fig. 3.5 [26,28].
However, the CGP method exhibits several limitations that make this
process unsuitable for industrial applications. It is difficult to apply very
Severe Plastic Deformation Methods for Sheets 119
Longitudinal
Sample
Transverse
direction (TD) direction (LD)
Bottom die
high strains because of relatively free forming of the sample during the
CGP processing. The sample surface is free, and the hydrostatic compres-
sive stress is relatively low [29]. This increases the possibility of the forma-
tion of cracks at higher strains [30]. Besides, it is hard to process large
samples using this process.
Downward force
n
io
Tool rotation ct
dire
Shoulder
ing
Friction stir e ld
W
welded region
Pin
Guide roll
Upper die
0.85 t0
t0
Feeding roll
t0
Lower die
thicknesses of the inlet and outlet channels are almost the same, while at
the deformation zone between rolls the thickness is decreased to
B0.850.95 t0 from t0. However, the sheet thickness at the outlet is
equal to the initial thickness. The diameter of the feeding and guide rolls,
their rotational speed, the frictional behavior of rolls and dies, the sheet
properties, and thickness variation are the main effective parameters of
this process. The ECAR process is a counterpart to the ECAP method,
which is suitable for processing sheets or long rods.
Figure 3.10 (A) Schematic of the discontinuous and (B) continuous RCS process for
SPD processing of sheet materials [8].
The equivalent plastic strain at each pass can be calculated from the fol-
lowing equation [9]:
t0
ε 5 lnð1 1 Þ (3.10)
2R
V1>V2
V1
V2
Figure 3.13 Schematic of the CFAE method: 1—driving roll, 2—sheet workpiece, 3—
workpiece support block, 4—die assembly, 5 and 6—first and second extrusion
channels, respectively [11].
the sample. The process may be repeated to apply ultrahigh plastic strains.
The CFAE technique offers several advantages, including being
suitable for processing industrial quantities of metals (mainly sheets, but
also bars and rods), and less extrusion force due to minimized die friction.
Offset
are applied to the sample repeatedly. The strain value per pass is relatively
low (B0.1), and many passes are required to apply larger strain similar to
that of the SPD methods. The simplicity of the procedure is its main
advantage. However, several disadvantages exist in this method. Low
strain per pass, very low hydrostatic compressive stresses, and very low
shear strain may be considered critical challenges. It is therefore hard to
achieve UFG structures and achieve high-strength metals with this
method [45,46].
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