Optimization of ECMAP parameters in production of ultra-fine grained Al1050 strips using Grey relational analysis

Production of lightweight metals with a higher strength to weight ratio is always the main goal of researchers. In this article, equal channel multi angular pressing (ECMAP) process as one of the most appealing severe plastic deformation (SPD) methods on production of ultra-fine grained (UFG) materials studied. Two main routes A and C investigated by FEM and compared with each other from different aspects of view. ABAQUS commercial software used to evaluate the maximum strain, maximum required force and strain inhomogeneity index in both routes and obtained results of FEM verified by both theoretical calculations and experimental tests. It is inferred that although equivalent plastic strain (PEEQ) in route A is higher than that in route C, the strain homogeneity as a quality factor for route C is higher. So, route C selected for more investigation and optimization. Grey relational analysis used as the optimization method. Geometrical parameters taken as input variables and both inhomogeneity index and maximum required load taken as objectives. Then, the suggested tests by full factorial method were simulated by FEM. After optimization, it was concluded that the best set up belongs to experiment number 20 which the values of Φ1, ψ1 and ψ2 are 165°, 0° and 15°, respectively. Also, it is inferred that among geometrical parameters, die channel angle (Φ1) is the most effective parameter.