International Scientific Journals
of Scientific Technical Union of Mechanical Engineering "Industry 4.0"

The application of mathematical methods is one of the most rational approaches used to solve tasks of evaluating the efficiency of unconventional metal forming processes. Using computer simulation in the DEFORM-3D application software package, we performed virtual full factorial experiments for the processes of producing individual samples by equal-channel angular pressing (ECAP) and highpressure torsion (HPT) from the Mg-1%Ca magnesium alloy, taking assumptions into account. At the stage of the simulation task preparation, it was accepted that the most significant factors that influence the fabrication of defect-free semi-products by severe plastic deformation (SPD) via ECAP are the processing temperature and the number of processing cycles via route Вс. In both models, strain intensity was taken as the response parameter. To simulate the SPD process of HPT, the processing temperature and the number of revolutions were used as the main variable factors. In the virtual full factorial experiment, the effect of independent factors on strain intensity was evaluated. As a result of the experiments, regression equations were obtained, variants of the rational processing regimes for the investigated alloy were presented, and their effect on the response parameter was analyzed. The proposed and implemented numerical models allow us to recommend the ECAP processing of the Mg-1%Ca magnesium alloy at a deformation speed of 1.0 mm/s and temperature of about 350 °С for 2 – 4 cycles, and the HPT processing under a hydrostatic pressure of 6 GPa at room temperature with the number of revolutions from 3 to 5.

With the help of computer simulation in the DEFORM-3D software, there was performed a virtual full factorial experiment of the process of shear drawing. In the course of the experiment, the effect of independent parameters (drawing speed, die rotation rate, die angle and friction factor) on the strain intensity was evaluated. As a result of the experiment, a regression equation was derived and the most significant individual factors and their combinations, influencing the response parameters, were determined. Also, comparative results were presented for the processes of regular drawing and shear drawing. It was demonstrated that the process of shear drawing has a higher efficiency from the point of view of strain intensity.

With the use of computer modeling in the environment of the DEFORM-3D software, a virtual full factorial experiment has been conducted for the processing of commercially pure titanium by equal-channel angular pressing (ECAP) via the Conform scheme. In the course of the modeling, the effect of independent parameters (the rotation velocity of the working wheel, the friction factor on the lateral surfaces of the working wheel and the friction factor between the billet and the die) has been evaluated. As a result of the experiment, a regression equation has been obtained and the most important individual factors and their mutual combinations that influence the response parameter (strain intensity) have been identified.