Finite element analysis and die project of Twist Equal-Channel Angular Pressing (T-ECAP) using pure Cu and CuCrZr alloy

In this study, numerical simulations were conducted using finite element analysis with a Twist Equal-Channel Angular Pressing (T-ECAP) die, employing commercially pure Cu and Cu–0.7Cr–0.07Zr alloy. Six different combinations of twist angle ( ω ) and twist slope angle (β) were tested in a new die. The punch force ranged from 100 to 120 kN for the considered geometries, except for the ω = 90° and β = 45° configuration, where the maximum load reached 170–210 kN. Similar to effective strains, the center of the cross section exhibited lower effective stresses than the surfaces. In optimizing the T-ECAP die, the configuration that yielded reduced heterogeneity in the distribution of stresses and strains, coupled with a lower pressing load, was the die with φ = 120°, Φ = 22°, ω = 90°, and β = 25°. This configuration imposed an average effective strain of 3.5 per pass. Graphical abstract