Investigation of Effective Plastic Strain Heterogeneity and the Effect of Using Interface Sheet in Constrained Groove Pressing of Copper Sheet

Subject Areas :

Moein Gholami ¹ (PhD Candidate, Mechanical Engineering Department, University of Birjand, Birjand, Iran)
Ali Hasanabadi ² (Assistant Professor, Mechanical Engineering Department, University of Birjand, Birjand, Iran)

Received: 2023-01-09 Accepted : 2023-03-02 Published : 2023-02-01

Keywords: numerical analysis, Severe Plastic Deformation, Constricted Groove Pressing, Copper Sheet, Strain Distribution Heterogeneity,

Abstract :

The constrained groove pressing process is one of the most effective methods of severe plastic deformation to produce very fine-grained sheet metal. Numerical simulation is performed in several steps by finite element software in such a way that the output result of each step, which is strain-hardened, is used as the input of the next step. The finite element results of the obtained plastic effective strain distribution show that the strain changes along the longitudinal direction of the sample are oscillating. The relevant results also show that in the direction of thickness, the amount of strain in the middle of the sample is maximum and as it moves away from the center of the sample, the amount of strain decreases. In addition, the results of strain heterogeneity show that the strain heterogeneity factor in the longitudinal direction is 2.8 times the corresponding value in the thickness direction whereas the average plastic strain in the two directions differs only about 13.4%. Then, to improve the strain uniformity, steel sheets are placed at the top and bottom of the sample as interface sheets, and then the constrained groove pressing is applied. Using this method, it is observed that the degree of strain homogeneity in the first stage is improved compared to the conventional method of the constrained groove pressing process. By using this method, it can be seen that the amount of strain heterogeneity factor is reduced from 6.85 to 2 in the first stage.

References:

[1] Borhani, M. and Djavanroodi, F. 2012. Rubber pad-constrained groove pressing process: Experimental and finite element investigation. Materials Science and Engineering: A. 546(1):1-7.

[2] Sajadi, A., Ebrahimi, M. and Djavanroodi, F. 2012. Experimental and numerical investigation of Al properties fabricated by CGP process. Materials Science and Engineering: A. 552(1): 97-103.

[3] Peng, K., Su, L., Shaw, L.L. and Qian, K.W. 2007. Grain refinement and crack prevention in constrained groove pressing of two-phase Cu–Zn alloys. Scripta Materialia. 56(11): 987-990.

[4] Peng, K., Zhang, Y., Shaw, L.L. and Qian, K.W. 2009. Microstructure dependence of a Cu–38Zn alloy on processing conditions of constrained groove pressing. Acta Materialia, 57(18): 5543-5553.

[5] Nazari, F. and Honarpisheh, M. 2018. Analytical model to estimate force of constrained groove pressing process. Journal of Manufacturing Processes. 32: 11-19.

[6] Shirdel, A., Khajeh, A. and Moshksar, M. 2010. Experimental and finite element investigation of semi-constrained groove pressing process. Materials & Design. 31(2): 946-950.

[7] Ranaei, M.A., Afsari, A., Ahmadi. Brooghani, S. Y. and Moshksar, M. M. 2014. Microstructure, mechanical and electrical properties of commercially pure copper deformed severely by equal channel angular pressing. Modares Mechanical Engineering.14(15): 257-267.

[8] Nili Ahmadabadi, M., Shirazi, H., Ghasemi-Nanesa, H., Hossein Nedjad, S., Poorganji, B. and Furuhara, T. 2011. Role of severe plastic deformation on the formation of nanograins and nano-sized precipitates in Fe–Ni–Mn steel. Materials and Design. 32: 3526–31.

[9] Ivanisenko, Y.U., Valiev, R.Z. and Fecht, H.J. 2005. Grain boundary statistics in nanostructured iron produced by high pressure torsion. Materials Science and Engneering. 390:159–65.

[10] Horita, Z., Smith, D.J., Furukawa, M., Nemoto, M., Valiev, R.Z. and Langdon, T.G. 1996. An investigation of grain boundaries in submicrometergrained Al-Mg solid solution alloys using high-resolution electron microscopy.  Journal of Materials Research. 11(8):1880-1890.

[11] Saito, Y., Tsuji, N., Utsunomiya, H., Sakai, T. and Hong, R. G. 1998. Ultrafine grained bulk aluminum produced by accumulative roll bonding (ARB) process. Scripta Materialia. 39(9):1221-1227.

[12] Saito, Y., Tsuji, N., Utsunomiya, H. and Sakai, H. 1999. Novel ultra-high straining process for bulk materials—development of the accumulative roll-bonding (ARB) process. Acta Materilia. 47: 579–583.

[13] Faraji, G. and Kim, H.S. 2017. Review of principles and methods of severe plastic deformation for producing ultrafine-grained tubes. Materials Science and Technology. 33(8): 905-923.

[14] Torabzadeh, H. and Faraji, G. 2016. A review of the production of ultrafine grained and nanograined metals by applying severe plastic deformation. Modares Mechanical Engineering. 16(6): 271-282.

[15] Shin, D.H., Park, J.J., Kim, Y.S. and Park, K.T. 2002. Constrained groove pressing and its application to grain refinement of aluminum. Material Science and Engineering: A. 328(1-2): 98–103.

[16] Sajadi, A., Ebrahimi, M. and Djavanroodi, F. 2012. Experimental and numerical investigation of Al properties fabricated by CGP process. Materials Science and Engineering: A. 552: 97-103.

[17] Honarpisheh, M., Tavajjohi, M.H. and Nazari, F. 2019. Experimental and Numerical Study of Severe Plastic Deformation in the Constrained Groove Pressing Process on the Pure Copper Sheets. Modares Mechanical Engineering. 19(2): 269-280.

[18] Tavajjohi, M.H.  and  Honarpisheh, M. 2021. Experimental and numerical study of the longitudinal and transverse residual stresses distribution in the constrained groove pressing process of pure copper sheets. Proceedings of the Institution of Mechanical Engineers, Part L: Journal of Materials: Design and Applications. 236(1): 97-109.

[19] Nazari, F., Honarpisheh, M. and Zhao, H. 2021. Effect of the uncertainty of multi-cut contour method and friction coefficient on residual stresses of constrained groove pressing process. Proceedings of the Institution of Mechanical Engineers, Part C: Journal of Mechanical Engineering Science. 235(11):2039-2052

[20] Niranjan, G. G. and Chakkingal, U. 2010. Deep drawability of commercial purity aluminum sheets processed by groove pressing, Journal of Materials Processing Technology. 210(11): 1511-1516.

[21] Hosseini, E. and Kazeminezhad, M. 2010. Integration of physically based models into FE analysis: Homogeneity of copper sheets under large plastic deformations. Computational Materials Science. 48(1): 166-173.

[22] Wang, Z.S., Guan, Y. and Zhong, C. 2015. Influences of die structure on constrained groove pressing of commercially pure Ni sheets. Journal of Materials Processing Technology. 215: 205-218.

[23] Wang, Z.S., Guan, Y.J. and Zhong, C.K. 2014. Effects of Friction on Constrained Groove Pressing of Pure Al Sheets. Advanced Materials Research. 926: 81-84.

[24] Yadav, P.C., Sinhal, A., Sahu, S., Roy, A. and Shekhar, S. 2016. Microstructural inhomogeneity in constrained groove pressed Cu-Zn alloy sheet. Journal of Materials Engineering and Performance. 25(7): 2604-2614.

[25] Callister, W.D. and Rethwisch, D.G. 2014. Materials Science and Engineering. 9th Edition. Wiley.

[26] Siddesha1, H.S., Shantharaja, M., DilipKumar, K. and Umesh, C.K. 2015. Experimental and computational simulation of production ultra-fine grain structure processed by CGP. International Journal of Advance Research In Science And Engineering. 14(2): 580-591.

[27] Kumara, S., Hariharanb, K., Digavallia, R. K. and Paulc, S. K. 2019. Accounting Bauschinger effect in the numerical simulation of constrained groove pressing process. Journal of Manufacturing Processes. 38: 49–62.

[28] Eftekhari Shahri, S.E., Gholami, M. and Rakhshkhorshid, M. 2022. Numerical-experimental study of die geometry in the constrained groove pressing of 6061 aluminum sheets. doi:10.1177/09544054221138161.

[29] Singh, R., Agrahari, S., Yadav, S.D. and Kumar, A. 2021. Microstructural evolution and mechanical properties of 316 austenitic stainless steel by CGP. Materials Science and Engineering: A. 812: 141105.

[30] Wang, Z.S., Guan, Y.J. and Liang, P. 2014. Deformation efficiency, homogeneity, and electrical resistivity of pure copper processed by constrained groove pressing. Rare Metals. 33: 287–292.

[31] Shahmirzaloo, A., Faraji, G. and Safari, M., Mohammadinejad, S. 2018. Interface sheet-constrained groove pressing as a modified severe plastic deformation process. Materials Science and Technology. 34(14): 1669-1678.