Comparison of the plastic strain distribution during equal-channel angular pressing (ECAP) using 2D and 3D FEM modeling

The plastic flow of a copper billet calculated using 2D and 3D finite element modeling are compared during a single extrusion of equal-channel angular pressing. Both models predict deformation heterogeneity irrespective of material behavior, die geometry and friction conditions. On the symmetry plane where the numerical approaches can be compared, their strain distributions differ, especially as the processing conditions deviate from the ideal conditions. Overall the three-dimensional finite element model calculates lower plastic strains than the two-dimensional model.