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Equal channel angular pressing (ECAP) process of AA7075 billet with the copper casing is comprehensively investigated. Firstly, ECAP process is simulated based on finite element method (FEM) in ABAQUS software and then is verified in comparison to the experimental data. The design of experiments using response surface methodology (RSM) is performed in order to investigate the processing parameters. The main effect of four considered parameters (channel angle, corner angle, friction coefficient and thickness of casing) on the maximum required force and strain was studied. Also, the regression models for estimating the maximum forming force and strain are represented in high reliability using analysis of variance (ANOVA). The results indicated that channel angle by 93.5% of contribution is the most effective parameter on the required forming force. It is concluded that the thickness of copper casing does not affect the forming force. Also, all terms of the presented regression model are effective on the strain value, according to the obtained results. Based on ANOVA results, channel and corner angel are the most effective parameters on the strain by 80 and 16% of the contribution, respectively. Also, the friction coefficient and the thickness of copper casing have almost no significant effects on the strain. doi: 10.5829/ije.2020.33.12c.15

Study on Equal Channel Angular Pressing Process of AA7075 with Copper Casing by Finite Element-response Surface Couple Method