F. Zaïri

Finite Element Analysis of Plastic Strain Distribution in Multipass ECAE Process of High Density Polyethylene

Equal channel angular extrusion (ECAE) is a relatively novel forming process to modify microstructure via severe plastic deformation without modification of the sample cross section. In this study, an optimized design of die geometry is presented, which improves homogeneity of the plastic deformation and decreases the pressing force required for extrusion. Then, a typical semicrystalline polymer (high density polyethylene) was subjected to multipass ECAE using two different processing routes: route A where the sample orientation is kept constant between passes and route C where the sample is rotated by 180 deg. Compression tests at room temperature and under different strain rates were used to identify the material parameters of a phenomenological elastic-viscoplastic model. Two-dimensional finite element analysis of ECAE process was carried out, thus allowing to check out the homogeneity of the plastic strain distribution. The effects of die geometry, number of passes, processing route, and friction coefficient on the plastic strain distribution were studied. The simulations were performed for three channel angles (i.e., 90 deg, 120 deg, and 135 deg), considering different corner angles. According to simulation results, recommendations on the angular extrusion of the polymer are provided for improving die and process performance.

Analysis of Polypropylene Deformation in a 135° ECAE Die: Experiments and Three-Dimensional Finite Element Simulations

Plastic deformation of polypropylene (PP) resulting from equal channel angular extrusion (ECAE) process was investigated in a 135° die. A phenomenological elastic-viscoplastic constitutive model was identified and coupled with the three-dimensional finite element (FE) method in order to predict the different processing parameters governing the deformation behaviour of PP during the extrusion. An optimal agreement between FE results and experimental data was obtained for a friction coefficient of 0.2. A detailed three-dimensional FE analysis of stress-strain field distribution was then carried out. The effects of both the number of extrusion passes and the processing routes were experimentally highlighted. The results show that the pressing force decreases with the increase of the number of extrusion passes and reaches its saturation state rapidly for routes A and C while, for routes BA and BC, it requires a high number of passes.

Micromechanical Modeling of the Effective Viscoelastic Response of Polyamide-6-Based Nanocomposites Reinforced with Modified and Unmodified Montmorillonite Clay

A micromechanics-based approach using a self-consistent scheme based on the double-inclusion model is adopted to develop a pertinent model for describing the viscoelastic response of polymer/clay nanocomposites. The relationship between the intercalated nanostructure and the effective nanocomposite stiffness is constructed using an equivalent stiffness method in which the clay stacks are replaced by homogeneous nanoparticles with predetermined equivalent anisotropic stiffness. The capabilities of the proposed micromechanics-based model are checked by comparing with the experimental viscoelastic (glassy to rubbery) response of two polyamide-6-based nanocomposite systems reinforced with a modified montmorillonite clay (Cloisite 30B) and an unmodified sodium montmorillonite clay (Cloisite Na+), favoring, respectively, exfoliation and intercalation states.

Successive Translucent and Opaque Shear Bands Accompanied by a Pronounced Periodic Waves Observed in a Polypropylene (PP) Processed by Single ECAE Pass

The equal channel angular extrusion (ECAE) is an ingenious severe plastic deformation process used to modify texture and microstructure without reducing sample cross-section. The ECAE of polypropylene (PP) was conducted under various extrusion velocities and back-pressure levels using a 90° die. The application of single ECAE pass to PP was meticulously investigated at room temperature. The ECAE-induced deformation behaviour was examined in relation to the load versus ram displacement curves. Depending on extrusion conditions, PP displayed various types of plastic flow. For ram velocities beyond 4.5 mm/min, severe shear bands consisting of successive translucent and opaque bands were observed, accompanied on the top surface by more or less pronounced periodic waves. Although the application of a back-pressure significantly reduced the wave and shear-banding phenomena, slightly inhomogeneous shear deformation was still observed. Shear bands were only suppressed by decreasing extrusion velocity. The strain-induced crystalline microstructure was investigated by X-ray scattering. Shear-banded samples exhibited a strong texturing of the (hk0) planes along the shear direction in the translucent bands whereas perfect crystalline isotropy appeared in the opaque bands. Application of backpressure and/or reducing ram velocity resulted in uniform texturing along the extruded sample. Yet, texturing changed from single shear to twin-like shear orientation about the shear direction. Mechanical properties changes of the extruded specimens due to back-pressure and extrusion velocity effects were analyzed via uniaxial tensile tests. The tensile samples displayed multiple strain localizations in shear-banded materials whereas quite homogeneous deformation appeared for non-banded ones. These effects were connected with the crystalline texturing. The results also revealed significant increase in the strain hardening after ECAE. Full-field strain was measured under tensile loading using an optical strain measuring technique based upon Digital image correlation technique, suitable for large deformation, which confirms these effects.