Abstract
To improve the industrialization of the severe plastic deformations (SPD) technology for magnesium (Mg) alloy, a new extrusion-shear (ES) process has been explored and widely investigated owing to its potential ability to produce ultra-fine-grained microstructures in Mg alloys. It is crucial to understand the effect of die design on the deformation behavior, strain distribution, and load requirements during ES process. Three-dimensional geometric models with different channel angles (135°, 120°) in the ES dies have been designed. The plastic deformation heterogeneities of ES process with different channel angles have been analyzed from the simulation results. The results can be summarized as follows. The equivalent strains and loads during the whole ES process decrease with the increase of channel angles. The decrease of channel angle could improve the deformation inhomogeneity of ES process. Smaller channel angles could promote the higher cumulative strains and finer subgrains. The analysis results show that finer and more uniform microstructures can be obtained if channel angles in the ES dies are appropriate. It is demonstrated that the predicted results are in good agreement with experiments results and the theoretical calculations. Numerical simulations and experiments could help to understand the deformation behaviors of AZ31 Mg alloy during ES.
Article PDF
Similar content being viewed by others
Avoid common mistakes on your manuscript.
References
Segal VM, Reznikov VI, Drotyshevkij AE (1981) Plastic working of metals by simple shear. Russ Metall 1:99–105
Iwahashi Y, Horita Z, Nemoto M, Langdon TG (1998) The process of grain refinement in equal-channel angular pressing. Acta Mater 46:17–31
Raghavan S (2001) Computational simulation of the equal-channel angular extrusion process. Scr Mater 44:91–96
Jiang H, Fan Z, Xie C (2007) 3D finite element simulation of deformation behavior of CP-Ti and working load during multi-pass equal channel angular extrusion. Mater Sci Eng A 485:409–414
Gong X, Li H, Kang SB, Cho JH, Li S (2010) Microstructure and mechanical properties of twin-roll cast Mg-4.5Al-1.0Zn alloy sheets processed by differential speed rolling. Mater Des 31:1581–1587
Gong X, Kang SB, Li S, Cho JH (2009) Enhanced plasticity of twin-roll cast ZK60 magnesium alloy through differential speed rolling. Mater Des 30:3345–3350
Matsuyama K, Miyahara Y, Horita Z, Langdon TG (2003) Developing superplasticity in a magnesium alloy through a combination of extrusion and ECAP. Acta Mater 51:3073–3084
Matsubara K, Miyahara Y, Horita Z, Langdon TG (2004) Achieving enhanced ductility in a dilute magnesium alloy through severe plastic deformation. Metall Mater Trans A 35A:1734–1744
Orlov D, Raab G, Lamark TT, Popov M, Estrin Y (2011) Improvement of mechanical properties of magnesium alloy ZK60 by integrated extrusion and equal channel angular pressing. Acta Mater 59:375–385
Hu HJ, Zhang DF, Zhang JP (2010) Microstructures in an AZ31 magnesium alloy rod fabricated by a new SPD process based on physical simulator. Trans Nonferrous Met Soc China 3:478–483
Kong F, Ma J, Kovacevic R (2011) Numerical and experimental study of thermally induced residual stress in the hybrid laser–GMA welding process. J Mater Process Technol 211:1102–1111
Ma J, Kong F, Kovacevic R (2012) Finite-element thermal analysis of laser welding of galvanized high-strength steel in a zero-gap lap joint configuration and its experimental verification. Mater Des 36:348–358
Ma J, Kong F, Carlson B, Kovacevic R (2013) Two-pass laser welding of galvanized high-strength dual-phase steel for a zero-gap lap joint configuration. J Mater Process Technol 213(3):495–507
Hu H, Yang M, Gong X, Li G (2006) Optimization of casting processes based on computer numerical simulation. Ordnance Mater Sci Eng 29:51–53
Gong X, Anderson T, Chou K (2014) Review on powder-based electron beam additive manufacturing technology. Manuf Rev 1:1–12
Gong X, Cheng B, Price S, Chou K (2013) Powder-bed electron-beam-melting additive manufacturing: powder characterization, process simulation and metrology. ASME District F-ECTC 2013: Early Career Technical Conference, Birmingham, Alabama, USA, November 2–3, 59–66
Qin F, Gong X, Chou K (2011) Size effects in cutting with a diamond-coated tool. Proceedings of the ASME 2011 International Manufacturing Science and Engineering Conference, Corvallis, OR, USA, June 13–17, 267–273
Hu HJ, Huang WJ (2013) Studies on wears of ultrafine-grained ceramic tool and common ceramic tool during hard turning using Archard wear model. Int J Adv Manuf Technol 69:31–39
Jiang JF, Wang Y, Qu JJ, Du ZM, Luo SJ (2010) Preparation and thixoforging of semisolid billet of AZ80 magnesium alloy. Trans Nonferrous Met Soc China 20:1731–1736
Li RX, Li RD, Bai YH, Qu YD, Yuan XG (2010) Effect of specific pressure on microstructure and mechanical properties of squeeze casting ZA27 alloy. Trans Nonferrous Met Soc China 20:59–63
Figueiredo RB, Cetlin PR, Langdon TG (2007) The processing of difficult-to-work alloys by ECAP with an emphasis on magnesium alloys. Acta Mater 55:69–79
Hu HJ, Fan JZ, Zhai ZY, Wang H, Li YY, Gong XB (2014) Physical fields evolution and microstructures for compound extrusion of AZ31 magnesium alloy. Russian J Non-Ferrous Metals 55:254–262
Hu HJ, Huang WJ (2013) Effects of turning speed on high-speed turning by ultrafine-grained ceramic tool based on 3D finite element method and experiments. Int J Adv Manuf Technol 67:907–915
Mofid MA, Abdollah-zadeh A, Hakan Gür C (2014) Investigating the formation of intermetallic compounds during friction stir welding of magnesium alloy to aluminum alloy in air and under liquid nitrogen. Int J Adv Manuf Technol 71:1493–1499
Feng F, Huang S, Hu J, Meng Z, Lei Y (2013) Analysis of the bulging process of an AZ31B magnesium alloy sheet with a uniform pressure coil. Int J Adv Manuf Technol 69(5–8):1537–1545
Wu G, Hu H, Gong X, Zhang W, Wang K, Dong T (2007) Application and development of casting process parameterized graph library based on AutoCAD software. Foundry Technol 28:535–537
Wu ZG, Song M, He YH (2009) Effects of Er on the microstructure and mechanical properties of an as-extruded Al–Mg alloy. Mater Sci Eng A 504:183–187
Song M, He Y, Wu Z, Huang B (2009) Multi-scale model for the ductility of multiple phase materials. Mech Mater 41:622–633
Song M, Wu Z, He Y (2008) Effects of Yb on the mechanical properties and microstructures of an Al–Mg alloy. Mater Sci Eng A 497:519–523
Qian Z, Chumbley LS, Misra S, Miller G, Pecharsky VK, Gschneidner KA, Ahn K, Chernyshov AS, Singh NK (2009) Electron microscopy examination of R5T4 alloys, where R = Ho, Yb and Gd, and T = Si, Ge, Ga and Sb. Acta Mater 57:3374–3381
Cao Q, Chumbley LS, Qian Z (2010) Thermal stability of RE5 (SixGe1 − x)3 plates in RE5(SixGe1 − x)4 alloys, where RE = Gd and Ho. Intermetallics 18:1021–1026
Qian Z, Chumbley S, Johnson E (2011) The effect of specimen dimension on residual stress relaxation of carburized and quenched steels. Mater Sci Eng A 529:246–252
Qian Z, Chumbley S, Karakulak T, Johnson E (2013) The residual stress relaxation behavior of weldments during cyclic loading. Metall Mater Trans A 44:3147–3156
Rajakumar S, Razalrose A, Balasubramanian V (2013) Friction stir welding of AZ61A magnesium alloy. Int J Adv Manuf Technol 68(1–4):277–292
Pan FS, Zhang J, Wang JF, Yang MB, Han EH, Chen RS (2010) Key R&D activities for development of new types of wrought magnesium alloys in China. Trans Nonferrous Met Soc China 20:1249–1258
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Hu, HJ., Wang, H., Zhai, ZY. et al. Effects of channel angles on extrusion-shear for AZ31 magnesium alloy: modeling and experiments. Int J Adv Manuf Technol 76, 1621–1630 (2015). https://doi.org/10.1007/s00170-014-6353-y
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-014-6353-y