Hostname: page-component-586b7cd67f-dsjbd Total loading time: 0 Render date: 2024-11-22T22:02:09.871Z Has data issue: false hasContentIssue false
  • English
  • Français

Deformation mechanics and microstructure evolution during indirect extrusion in (sub) mm-scale samples

Published online by Cambridge University Press:  22 March 2016

Marzyeh Moradi ,
Saurabh Basu  and
M. Ravi Shankar
Marzyeh Moradi
Affiliation:
Department of Industrial Engineering, University of Pittsburgh, Pittsburgh, Pennsylvania 15213, USA
Saurabh Basu
Affiliation:
Department of Mechanical Engineering, George W. Woodruff School of Mechanical Engineering, Georgia Institute of Technology, Atlanta, Georgia 30313, USA
M. Ravi Shankar*
Affiliation:
Department of Industrial Engineering, University of Pittsburgh, Pittsburgh, Pennsylvania 15213, USA
*
a) Address all correspondence to this author. e-mail: [email protected]
Get access

Abstract

Mechanics of deformation in miniaturized indirect extrusion (IE) and their resulting process outcomes are shown to be dependent on the dimensional scale of the plastic deformation zone. Using optically transparent dies as prototypes, the effect of process length-scales on the strain, strain-rate, and rotation fields is elucidated using digital image correlation. In this regard, in situ experiments were performed on commercially pure Lead (Pb) and Aluminum (Al 1100) as prototypical nonwork/work hardening materials. By overlaying these measurements with microstructural characterization via electron backscattered diffraction, the effect of deformation volume on process–structure mappings is identified. Herein, visco-plastic self-consistent framework-based modeling of the evolution of crystallographic textures was investigated to achieve insights into the trajectories of microstructure evolution and process outcomes during IE. These findings provide a beneficial background about characteristics of plastic deformation zone and its distribution to optimize and control the properties of miniaturized components.

Keywords

extrusionmicrostructurecrystallographic structure
Type
Articles
Information
Journal of Materials Research , Volume 31 , Issue 8 , 28 April 2016 , pp. 1096 - 1112
Copyright
Copyright © Materials Research Society 2016 

Access options

Get access to the full version of this content by using one of the access options below. (Log in options will check for institutional or personal access. Content may require purchase if you do not have access.)

References

REFERENCES

Basu, S., Zhiyu, W., and Saldana, C.: Anomalous evolution of microstructure and crystallographic texture during indentation. Acta Mater. 105, 25–34 (2016).CrossRefGoogle Scholar
Basu, S. and Shankar, M.R.: Microstructure evolution during severe shear deformation at small length-scales. Scr. Mater. 73, 52–54 (2014).Google Scholar
Chakrabarty, J.: Theory of Plasticity (Butterworth-Heinemann, Oxford, 2012).Google Scholar
Yen, Y.C., Jain, A., and Altan, T.: A finite element analysis of orthogonal machining using different tool edge geometries. J. Mater. Process. Technol. 146(1), 72–81 (2004).CrossRefGoogle Scholar
Geiger, M., Kleiner, M., Eckstein, R., Tiesler, N., and Engel, U.: Microforming. CIRP Ann. Manuf. Technol. 50(2), 445–462 (2001).CrossRefGoogle Scholar
Fu, M.W. and Chan, W.L.: A review on the state-of-the-art microforming technologies. Int. J. Adv. Manuf. Technol. 67, 2411–2437 (2013).CrossRefGoogle Scholar
Basu, S. and Shankar, M.R.: Spatial confinement-induced switchover in microstructure evolution during severe plastic deformation at micrometer length scales. Acta Mater. 79, 146–158 (2014).CrossRefGoogle Scholar
Vollertsen, F., Niehoff, H.S., and Hu, Z.: State of the art in micro forming. Int. J. Mach. Tool Manuf. 46(11), 1172 (2006).CrossRefGoogle Scholar
Hosford, W.F. and Caddell, R.M.: Metal Forming: Mechanics and Metallurgy (Cambridge University Press, New York, 2011).CrossRefGoogle Scholar
Rollett, A., Humphreys, F.J., Rohrer, G.S., and Hatherly, M.: Recrystallization and Related Annealing Phenomena (Elsevier, Oxford, 2004).Google Scholar
Kumar, M., Schwartz, A.J., and King, W.E.: Microstructural evolution during grain boundary engineering of low to medium stacking fault energy fcc materials. Acta Mater. 50(10), 2599–2612 (2002).CrossRefGoogle Scholar
Moradi, M., Basu, S., and Shankar, M.R.: In situ measurement of deformation mechanics and its spatiotemporal scaling behavior in equal channel angular pressing. J. Mater. Res. 30(6), 798–810 (2015).CrossRefGoogle Scholar
Zienkiewicz, O.C. and Godbole, P.N.: Flow of plastic and visco-plastic solids with special reference to extrusion and forming processes. Int. J. Numer. Methods Eng. 8, 1–16 (1974).CrossRefGoogle Scholar
Wang, H., Wu, P., Tomé, C., and Huang, Y.: A finite strain elastic–viscoplastic self-consistent model for polycrystalline materials. J. Mech. Phys. Solids 58(4), 594–612 (2010).CrossRefGoogle Scholar
Rees, D.: Basic Engineering Plasticity: An Introduction with Engineering and Manufacturing (Butterworth-Heinemann, Oxford, 2012).Google Scholar
Hosford, W.F. and Caddell, R.M.: Metal Forming (Prentice Hall, Oxford, 1993).Google Scholar
Turkovich, B.F.V. and Black, J.T.: Micro-machining of copper and aluminum crystals. J. Eng. Ind. 92(1), 130–134 (1970).CrossRefGoogle Scholar
Lee, E., Mallett, R., and Yang, W.H.: Stress and deformation analysis of the metal extrusion process. Comput. Methods Appl. Mech. Eng. 10(3), 339–353 (1977).CrossRefGoogle Scholar
Teoh, S.H. and Lee, K.H.: Fracture of Engineering Materials and Structures (Elsevier, Oxford, 1991).CrossRefGoogle Scholar
Prime, M.B. and Hill, M.R.: Residual stress, stress relief, and inhomogeneity in aluminum plate. Scr. Mater. 46(1), 77–82 (2002).CrossRefGoogle Scholar
Handbook, M.: Properties and selection: nonferrous alloys and pure metals (American Society for Metals, Metals Park, 1979).Google Scholar
Rosochowski, A., Presz, W., Olejnik, L., and Richert, M.: Micro-extrusion of ultra-fine grained aluminium. Int. J. Adv. Manuf. Technol. 33(1–2), 137–146 (2007).CrossRefGoogle Scholar
Bakhshi-Koybari, M.: A theoretical and experimental study of friction in metal forming by the use of the forward extrusion process. J. Mater. Process. Technol. 125, 369–374 (2002).CrossRefGoogle Scholar
Chang, C.C. and Wang, T.C.: Effects of grain size on micro backward extrusion of copper. Adv. Mater. Res. 83–86, 1092–1098 (2010).Google Scholar
Chan, W.L., Fu, M.W., and Yang, B.: Study of size effect in micro-extrusion process of pure copper. Mater. Des. 32(7), 3772–3782 (2011).CrossRefGoogle Scholar
Cardarelli, F.: Materials Handbook (Springer, London, 2000).CrossRefGoogle Scholar
Tiesler, N. and Engel, U.: Microforming-effects of miniaturization. In 8th International Conference on Metal Forming (Rotterdam, Balkema, 2000); p. 355.Google Scholar
Fu, M.W. and Chan, W.L.: Micro-Scaled Products Development via Microforming (Springer, London, 2014).CrossRefGoogle Scholar
Hall, H.O.: The deformation and ageing of mild steel: III. Discussion of Results. Proc. Phys. Soc. London, Sect. B 64(9), 747 (1951).CrossRefGoogle Scholar
Petch, N.J.: The cleavage strength of polycrystals. J. Iron Steel Inst. 174, 25–28 (1953).Google Scholar
Armstrong, R., Codd, I., Douthwaite, R.M., and Petch, N.J.: The plastic deformation of polycrystalline aggregates. Philos. Mag. 7(73), 45–58 (1962).CrossRefGoogle Scholar
Thompson, A.W., Baskes, M.I., and Flanagan, W.F.: The dependence of polycrystal work hardening on grain size. Acta Mater. 21(7), 1017–1028 (1973).CrossRefGoogle Scholar
Basu, S. and Shankar, M.R.: Crystallographic textures resulting from severe shear deformation in machining. Metall. Mater. Trans. A 46(2), 801–812 (2015).CrossRefGoogle Scholar
Kalidindi, S.R., Bronkhorst, C.A., and Anand, L.: Crystallographic texture evolution in bulk deformation processing of FCC metals. J. Mech. Phys. Solids 40(3), 537–569 (1992).CrossRefGoogle Scholar
Lebensohn, R.A. and Tomé, C.N.: A self-consistent anisotropic approach for the simulation of plastic deformation and texture development of polycrystals: Application to zirconium alloys. Acta Metall. Mater. 41(9), 2611–2624 (1993).CrossRefGoogle Scholar
Hughes, D.A. and Hansen, N.: High angle boundaries formed by grain subdivision mechanisms. Acta Metall. 45(9), 3871–3886 (1997).Google Scholar
Demir, E., Raabe, D., Zaafarani, N., and Zaefferer, S.: Acta Mater. 57(2), 559–569 (2009).CrossRef
Acharya, A. and Knops, R.J.: Investigation of the indentation size effect through the measurement of the geometrically necessary dislocations beneath small indents of different depths using EBSD tomography. J. Elasticity 114(2), 275–279 (2013).CrossRefGoogle Scholar
Fleck, N.A. and Hutchinson, J.W.: An observation on the experimental measurement of dislocation density. Adv. Appl. Mech. 33, 295–361 (1997).CrossRefGoogle Scholar
Fleck, N.A., Muller, G.M., Ashby, M.F., and Hutchinson, J.W.: Strain gradient plasticity: Theory and experiment. Acta Metall. Mater. 42(2), 475–487 (1993).CrossRefGoogle Scholar
Engel, U. and Eckstein, R.: Microforming–from basic research to its realization. J. Mater. Process. Technol. 125–126(9), 35–44 (2002).CrossRefGoogle Scholar
Poole, W.J., Ashby, M.F., and Fleck, N.A.: Micro-hardness of annealed and work-hardened copper polycrystals. Scr. Mater. 34(15), 559–564 (1996).CrossRefGoogle Scholar