Optimization of the Severe Plastic Deformation Processes for the Grain Refinement of Al6060 Alloy Using 3D FEM Analysis
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JMEPEG DOI: 10.1007/s11665-010-9783-1
Optimization of the Severe Plastic Deformation Processes for the Grain Refinement of Al6060 Alloy Using 3D FEM Analysis E. Lo´pez-Chipres, E. Garcı´a-Sanchez, E. Ortiz-Cuellar, M.A.L. Hernandez-Rodriguez, and R. Cola´s (Submitted April 12, 2010; in revised form October 14, 2010) An analysis in 3D by means of the finite element method was carried out to study three processes for producing bulk fine-grained materials: dual equal channel angular pressing (DECAP), equal channel angular pressing, and multi-axial forging. For this purpose, a commercial Al6060 alloy in solution heat treatment conditions was utilized. The effect of different values of the coefficients of friction (l), the plastic flow, the strain hardening behavior, and the effective strain were analyzed. The results obtained from the simulation are in good agreement with the experimental studies. The results indicate that the DECAP process improves the plastic flow and promotes homogeneous strain distribution and grain refinement due to an increase in components of the shear deformation, back-pressure effect, and the diminution of the coefficient of friction.
Keywords
aluminum alloys, finite element method, severe plastic deformation processes, ultrafine-grained microstructure
1. Introduction Fine-grained materials have attracted considerable interest among researchers, due to the presence of a large amount of grain boundary area resulting in unusual and extraordinary changes in mechanical and physical properties. Numerous severe plastic deformation (SPD) methods have been proposed to produce fine-grained materials by introducing large plastic strains into bulk materials. Nowadays, the development of aluminum alloys with ultrafine-grained structure is of practical interest. This is explained by the fact that considerable lowering of the grain size gives several technological advantages raising the strength and impact toughness of materials at room temperature (Ref 1-3). The techniques of SPD are defined as metal-forming processes in which a very large plastic strain is imposed on a bulk process to make an ultrafine-grained metal. Some of the applications of these materials produced by these processes are in lightweight parts with high strength for safety and reliability components with less impact in the environment (Ref 4). In conventional metal-forming processes, such as rolling, forging, and extrusion, the imposed plastic strain is limited; due to the reduction of the thickness and diameter. In order to impose an extremely large strain on the bulk metal
E. Lo´pez-Chipres, Facultad de Ciencias Quimicas, Universidad Jua´rez del Estado de Durango, Durango, Mexico; and E. Garcı´a-Sanchez, E. Ortiz-Cuellar, M.A.L. Hernandez-Rodriguez, and R. Cola´s, Facultad de Ingenieria Meca´nica y Ele´ctrica, Universidad Auto´noma de Nuevo Leo´n, Monterrey, Mexico. Contact e-mail: egs7710@ gmail.com.
Journal of Materials Engineering and Performance
without changing the shape many SPD processes have been developed. It has been reported that
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