Dual Twist Channel Angular Extrusion for Ultrafine-Grained Material Processing as an Advanced Severe Plastic Deformation Technique: A Finite Element Analysis

<ns3:p>Dual Twist Channel Angular Extrusion (DTCAE), a modified advanced Severe Plastic Deformation (SPD) technique, is investigated through Finite Element Analysis (FEA). The proposed technique is the cumulation of multiple deformations with Equal Channel Angular Pressing (ECAP) to enhance the process efficiency and strain induction. The DTCAE die facilitates a twist of 90°, before the 110° ECAP, a 45° twist after ECAP in the reverse direction, followed by the extrusion. The extrusion at the die exit introduces backpressure and ensures proper material flow in the die. DEFORM-3D finite element simulation software package is utilized for the deformation, flow characteristics, load requirement etc. The results of the DTCAE simulation revealed the homogeneous and higher amount of strain induction in the billet in comparison to single ECAP. Effective strain distribution contours, Load-stroke plot, and velocity vector map of the work material ensure the progressive deformation and homogeneous strain distribution, establishing the effectiveness of the advanced DTCAE process.</ns3:p>