Optimization of die geometry for tube channel pressing

Document Type : Research Paper


Ferdowsi University of Mashhad


Since tubes have numerous industrial applications, different attempts are focused on the severe plastic deformation processes of tubes. As an illustration, tube channel pressing (TCP) is an attractive process for this purpose since it can be used for processing of different sizes of tubes. However, more attempts are needed to improve the outcomes of TCP. For example, imposing of a greater strain besides reductions of the strain heterogeneity are the challenges of this process. This work is aimed to optimize the die geometry of TCP through a finite element simulation procedure verified by experiments in order to increase the imposed strain as well as to decrease the strain heterogeneity. Results show that the increase of die curvature radius causes decrease of imposed plastic strain and increase of strain heterogeneity. In addition, the minimum amount of die convex height for imposing of a reasonable strain through TCP is calculated considering the tube thickness and the channel angle. Besides this, the optimum die geometry is recommended in order to minimize the strain heterogeneity.


[1] V.M. Segal, Material processing by simple shear, Material science Engineering A. 197 (1995) 157–164.
[2] R.Z. Valiev, N.A. Krasilnikov, N.K. Tsenev, Plastic deformation of alloys with submicron-grained structure, Materials Science Engineering A. 137 (1991) 35-40.
[3] N. Tsuji, Y. Saito, H. Utsunomiya, S. Tanigawa, Ultrafine grained bulk steel produced by Accumulative Roll-Bonding (ARB) process, Scripta Materialia 40 (1999) 795–800.
[4] Y. Estrin, A. Vinogradov, Extreme grain refinement by severe plastic deformation: A wealth of challenging science, Acta Materialia 61 (2013) 782–817.
[5] M.S. Mohebbi, A. Akbarzadeh, Accumulative spin bonding (ASB) as a novel SPD process for fabrication of nanostructured tubes, Materials Science Engineering A 528 (2010) 180–188.
[6] L.S. Toth, M. Arzaghi, J.J. Fundenberger, B. Beausir, O. Bouaziz, R.A. Massion, Severe plastic deformation of metals by high-pressure tube twisting, Scripta Materialia 60 (2009) 175–177.
[7] A.V. Nagasekhar, U. Chakkingal, P. Venugopal, Candidature of equal channel angular pressing for processing of tubular commercial purity-titanium, Journal of Materials Processing Technologies, 173 (2006) 53–60.
[8] A.V. Nagasekhar, U. Chakkingal, P. Venugopal, Equal Channel Angular Extrusion of Tubular Aluminum Alloy Specimens—Analysis of Extrusion Pressures and Mechanical Properties, Journal of Manufacturing Processes 8 (2006) 112-120.
[9] A. Zangiabadi, M. Kazeminezhad, Development of a Novel Severe Plastic Deformation Method for Tubular Materials: Tube Channel Pressing (TCP), Materials Science and Engineering A 528 (2011) 5066-5072.
[10] M.H. Farshidi, M. Kazeminezhad, The effects of die geometry in tube channel pressing: Severe plastic deformation, Journal of Materials: Design and Application 230 (2016) 263–272.
[11] M.H. Farshidi, New geometry for TCP: severe plastic deformation of tubes, Iranian Journal of Materials Forming 3 (2016) 64-78.
[12] M. Javidikia, R. Hashemi, Analysis and Simulation of Parallel Tubular Channel AngularPressing of Al 5083 Tube, Transaction of the Indian Institute of Metals, accepted and awaiting publishing, DOI: 10.1007/s12666-017-1117-7.
[13] G. Faraji, F. Reshadi, M. Baniasadi, A New Approach for Achieving Excellent Strain Homogeneity in Tubular Channel Angular Pressing (TCAP) Process, Journal of Advanced Materials and Processing 2 (2014) 3-12.
[14] M.H. Farshidi, M. Kazeminezhad, Deformation behavior of 6061 aluminum alloy through tube channel pressing: Severe plastic deformation, Journal of Materials Engineering and Performance 21 (2012) 2099–2105.
[15] M.H. Farshidi, M. Kazeminezhad, H. Miyamoto, Microstructrual evolution of aluminum 6061 alloy through Tube Channel Pressing, Materials Science and Engineering A 615 (2014) 139-147.
[16] M. Kazeminezhad, E. Hosseini, Modeling of induced empirical constitutive relations on materials with FCC, BCC, and HCP crystalline structures: severe plastic deformation, International Journal of Advanced Manufacturing Technologies 47 (2010) 1033–1039.
[17] A. Kacem, A. Krichen, P.Y. Manach, S. Thuillier, J.W. Yoon, Failure prediction in the hole-flanging process of aluminium alloys, Engineering Fracture Mechanics 99 (2013) 251–265.
[18] M. Reihanian, R. Ebrahimi, M.M. Moshksar, D. Terada, N. Tsuji, Microstructure quantification and correlation with flow stress of ultrafine grained commercially pure Al fabricated by equal channel angular pressing (ECAP), Materials Characterization 59 (2008) 1312–1323.
[19] N. Medeiros, L.P. Moreira, J.D. Bressan, J.F.C. Lins, J.P. Gouvea, Upper-bound sensitivity analysis of the ECAE process, Materials Science and Engineering A 527 (2010) 2831–2844.
[20] C.J. Luis Perez, On the correct selection of the channel die in ECAP processes, Scripta Materialia 50 (2004) 387–393.
[21] V. Patil Basavaraj, U. Chakkingal, T.S. Prasanna Kumar, Effect of geometric parameters on strain, strain inhomogeneity and peak pressure in equal channel angular pressing – A study based on 3D finite element analysis, Journal of Manufacturing Process 17 (2015) 88–97.