Investigation into equal channel angular extrusion process of billet with internal defects

The shear plastic deformation behavior of a material during equal channel angular (ECA) extrusion is governed primarily by the die geometry, the material properties, and the process conditions. This study uses the commercial DEFORM™ 2D (two-dimensional) rigid-plastic finite element code to investigate the plastic deformation behavior of materials with internal defective voids during 1- and 2-turn ECA extrusion processing. The present simulations investigate the damage factor distributions, the total velocity distributions, the rotation angle distributions, the void dimension, and the stress-strain distributions around the defective voids under various extrusion conditions. The mesh element increase of the billet mesh in the 2-turn ECA extrusion process is also investigated. The present numerical results provide valuable insights into the shear plastic deformation behavior of materials containing defective voids in the ECA extrusion process.