Simulation study of the effect of different channel and curvature angles on the effective strain and process load in the tubular channel angular pressing (TCAP) process using a trapezoidal channel cross-section

Document Type : Original Article

Authors

1 MSc Graduate, Department of Mechanical Engineering, University of Kashan, Kashan, Iran

2 Associate Professor, Department of Mechanical Engineering, University of Kashan, Kashan, Iran

Abstract

Tubular channel angular pressing (TCAP) process is one of the new methods to produce tubes with very good mechanical and microstructural properties. The trapezoidal channel cross-section is preferred in this process due to its high strain homogeneity and low required load compared to other channel cross-sections. In this research, the TCAP process with a trapezoidal channel cross-section was modeled using different channel and curvature angles in Abaqus software and then one pass of the process was applied to annealed aluminum 6061 samples. After that, the effect of these angles on the effective strain as well as process load was shown. For validation, the results of the finite element method (FEM) were compared and analyzed with the analytical model. The results of the processed samples showed that reducing the channel and curvature angles increases the applied effective strain. By increasing the curvature angle, the strain homogeneity has increased, and as a result, the hardness and microstructure homogeneity have increased. The process load has also decreased with the increase of channel and curvature angles. Also, there was a good agreement between the FEM results and the analytical model.

Keywords

References

[1] Bagherpour E, Pardis N, Reihanian M, Ebrahimi R. An overview on severe plastic deformation: research status, techniques classification, microstructure evolution, and applications. The International Journal of Advanced Manufacturing Technology: 2019 Feb 19; 100:1647-94. doi: 10.1007/s00170-018-2652-z
[2] Honarpisheh M, Dehghani M, Haghighat E. Investigation of mechanical properties of al/cu strip produced by equal channel angular rolling. Procedia materials science: 2015 Jan 1; 11:1-5. doi: 10.1016/j.mspro.2015.11.002
[3] Nazari F, Honarpisheh M. Analytical and experimental investigation of deformation in constrained groove pressing process. Proceedings of the Institution of Mechanical Engineers. Part C: Journal of Mechanical Engineering Science: 2019 Jun; 233: 3751-9. doi: 10.1177/0954406218809738
[4] Aghababaei A, Honarpisheh M. Experimental and numerical investigation of residual stress distribution in Al-6061 tubes under using tubular channel angular pressing process by new trapezoidal channel. The Journal of Strain Analysis for Engineering Design: 2023 May; 58: 332-42. doi: 10.1177/03093247221113229
[5] Faraji G, Mashhadi MM, Kim HS. Tubular channel angular pressing (TCAP) as a novel severe plastic deformation method for cylindrical tubes. Materials Letters: 2011 Oct; 65(19-20):3009-12. doi: 10.1016/j.matlet.2011.06.039
[6] Faraji G, Mashhadi MM, Kim HS. Deformation behavior in tubular channel angular pressing (TCAP) using triangular and semicircular channels. Materials transactions: 2012 Jan;53(1):8-12. doi: 10.2320/matertrans.MD201107
[7] Faraji G, Reshadi F, Baniasadia M. A new approach for achieving excellent strain homogeneity in tubular channel angular pressing (TCAP) process. Journal of Advanced Materials and Processing: 2014 Feb;2(1): 3-12. [In Persian]
[8] Aghababaei A, Honarpisheh M. Investigation of Microstructure and Mechanical Properties of Al-6061 Tubes Processed by Tubular Channel Angular Pressing Process Having Trapezoidal Channel Geometry. Iranian Journal of Materials Forming: 2022 Apr; 9(2): 36-45. doi: 10.22099/ijmf.2022.42890.1214
[9] Shagwira H, Obiko JO, Mwema FM. Finite element method simulation of metal flow during Tubular Channel Angular Pressing (TCAP) of aluminium 7075. Advances in Materials and Processing Technologies: 2023 May; 24:1-23. doi: 10.1080/2374068X.2023.2216403
[10] Material Property Data (MatWeb). Aluminum 6061-O [Internet]. 2023 May [cited 2023 Sep 18] Available from: https://www.matweb.com
[11] Xu C, Furukawa M, Horita Z, Langdon TG. Using ECAP to achieve grain refinement, precipitate fragmentation and high strain rate super plasticity in a spray-cast Aluminum alloy. Acta materialia: 2003 Dec;51(20):6139-49. doi: 10.1016/S1359-6454(03)00433-6
[12] Xu C, Horita Z, Langdon TG. The evolution of homogeneity in processing by high-pressure torsion. Acta materialia: 2007 Jan; 55(1):203-12. doi: 10.1016/j.actamat.2006.07.029
[13] Nagasekhar AV, Yoon SC, Tick-Hon Y, Kim HS. An experimental verification of the finite element modelling of equal channel angular pressing. Computational materials science: 2009 Aug; 46(2): 347-51. doi: 10.1016/j.commatsci.2009.03.018
[14] Bok HH, Lee MG, Kim HD, Moon MB. Thermo-mechanical finite element analysis incorporating the temperature dependent stress-strain response of low alloy steel for practical application to the hot stamped part. Metals and Materials International: 2010 Apr; 16:185-95. doi: 10.1007/s12540-010-0405-0
Iranian Journal of Manufacturing Engineering
Volume 10, Issue 1 - Serial Number 63
Best Paper of ICME 2022
March 2023
Pages 30-37

Files

Share

How to cite

Statistics