Finite Element Analysis of Severe Plastic Deformation by Rectangular Vortex Extrusion

In this research, conventional extrusion and twist extrusion are combined to propose a new design for single-pass severe plastic deformation technique, which is called Rectangular Vortex Extrusion (RVE). The effects of different parameters like RVE die twist angle as well as friction condition at the die-sample interface were studied using finite element analysis. It was shown that RVE can be successfully performed as a single-pass severe plastic-deformation technique to impose high strain values within the sample. It was revealed that the die geometry has the primary role in imposing torsion on the sample, while friction does not significantly increase the process potential for imposing additional torsion. Meanwhile, friction at the interfaces was found to be effective for increasing the intensity of the velocity gradient within the deformation zone. The results show that increasing the die twist angle and friction condition have a synergetic effect on increasing the accumulated strain values.