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The present research aimed to optimise process parameters such as outer corner angle ( ψ  = 0°–36°), frictional coefficient ( μ  = 0–0.05), inner corner angle ( ω  = 0°–8°) and die channel angle ( φ  = 90°–120°) for the equal channel angular pressing (ECAP) die design considering a non-strain hardening material Al6061-T6 alloy using ABAQUS finite element analysis software in terms material flowability, corner gap formation, surface gap formation, induced strain intensity and strain distribution. The ECAP die having 100°  φ , 24°  ψ , 0.02  μ  and 8°  ω  provide better material flowability, (no corner gap formation and surface gap formation), moderate induced strain intensity and homogeneous distribution. The ECAP processing on the designed die effectively modifies the microstructure morphology of as-cast Al6061 alloy. The α-Al grain size decreases and roundness increases and the thicker grain boundary is altered into the thinner boundary, as an effect of this, hardness and tensile strength improved by 28.3% and 32.7%, respectively.

Equal channel angular pressing die design through finite element analysis method for non-strain hardening material