OPTIMIZATION AND INFLUENCE OF PROCESS PARAMETERS ON ECAD SECTION SHRINKAGE OF 7075 Al ALLOY
Keywords:
equal channel angular drawing, section shrinkage, orthogonal design, genetic algorithm
Abstract
The phenomenon of section shrinkage during the equal channel angular drawing (ECAD) process significantly impacts the dimensional precision of a specimen’s cross-section, posing a challenge for the industrial implementation of this forming technique. To address this problem, a numerical simulation of the 7075 Al alloy during the ECAD process was conducted using Deform-3D, which revealed the influence of process parameters on ECAD section shrinkage. Through analyzing the results of the orthogonal design, the importance of various process parameters on section shrinkage was researched using range analysis and analysis of variance. A multi-objective optimization approach utilizing a genetic algorithm was developed to determine the optimal process parameter combination, subsequently validated through ECAD experiments. The results demonstrate that shrinkage decreases as the inner and outer angles of the die increase, while it increases with higher friction coefficients and drawing speeds. Among these process parameters, the inner angle is found to have the most significant influence on shrinkage, followed by the friction coefficient and the outer angle, while the drawing speed has the least impact on shrinkage which can be considered negligible. Consequently, the optimal combination of process parameters is identified as an inner angle of 120°, an outer angle of 90°, and a friction coefficient of 0.11.
References
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36 Shuken S R, McNerney M W, Costs and benefits of popular P-value correction methods in three models of quantitative omic experiments. Analytical chemistry, 95 (2023) 5, 2732-2740, doi: 10.1021/acs.analchem.2c03719
2 Gao J, He T, Huo Y, Song M, Yao T, Yang W, Comparison of modified Mohr–Coulomb model and Bai–Wierzbicki model for constructing 3D ductile fracture envelope of AA6063. Chinese Journal of Mechanical Engineering, (2021) 34, 1-13, doi: 10.1186/s10033-021-00549-4
3 Tajally M, Emadoddin E, Mechanical and anisotropic behaviors of 7075 aluminum alloy sheets. Materials & Design, 32 (2011) 3, 1594-1599, doi: 10.1016/j.matdes.2010.09.001
4 Jia D, He T, Song M, Huo Y, Du X, Vereshchaka A, Li J, Hu H, Microstructure evolution of 7050 Al alloy fasteners during cold upsetting after equal channel angular pressing. Journal of Central South University, 30 (2023) 11, 3682-3695, doi: 10.1007/s11771-023-5464-8
5 Valiev R Z, Langdon T G, Principles of equal-channel angular pressing as a processing tool for grain refinement. Progress in materials science, 51(2006) 7, 881-981, doi: 10.1016/j.pmatsci.2006.02.003
6 Jia D, He T, Song M, Huo Y, Hu H, Effects of equal channel angular pressing and further cold upsetting process to the kinetics of precipitation during aging of 7050 aluminum alloy. Journal of Materials Research and Technology, (2023) 26, 5126-5140, doi: 10.1016/j.jmrt.2023.08.258
7 Li J, He T, Du X, Alexey V, Zhang J, Regulating hardness homogeneity and corrosion resistance of Al-Zn-Mg-Cu alloy via ECAP combined with inter-pass aging. Materials Characterization, (2024) 114489, doi: 10.1016/j.matchar.2024.114489
8 Zhang J, He T, Du X, Huo Y, Jia D, Chen X, Effect of Pre-Equal Channel Angular Pressing Homogenization on Microstructure and Mechanical Properties of As-Cast 7050 Al Alloy. Journal of Materials Engineering and Performance, (2024) 1059-9495, doi: 10.1007/s11665-024-09950-1
9 Chakkingal U, Suriadi A B, Thomson P F, Microstructure development during equal channel angular drawing of Al at room temperature. Scripta Materialia, 39 (1998) 6, 677-684, doi: 10.1016/S1359-6462(98)00234-6
10 Chakkingal U, Suriadi A B, Thomson P F, The development of microstructure and the influence of processing route during equal channel angular drawing of pure aluminum. Materials Science and Engineering: A, 266 (1999) 1-2, 241-249, doi: 10.1016/S0921-5093(98)01129-0
11 León J, Luis-Pérez C J, Analysis of stress and strain in the equal channel angular drawing process. Materials science forum, (2006) 526, 19-24, doi: 10.4028/www.scientific.net/MSF.526.19
12 Zisman A A, Rybin V V, Van Boxel S, Seefeldt M, Verlinden B, Equal channel angular drawing of aluminium sheet. Materials Science and Engineering: A, 427 (2006) 1-2, 123-129, doi: 10.1016/j.msea.2006.04.007
13 Pérez C L, Berlanga C, Pérez-Ilzarbe J, Processing of aluminium alloys by equal channel angular drawing at room temperature. Journal of materials processing technology, (2003) 143, 105-111, doi: 10.1016/S0924-0136(03)00329-7
14 Alkorta J, Rombouts M, De Messemaeker J, Froyen L, Sevillano J G, On the impossibility of multi-pass equal-channel angular drawing. Scripta materialia, 47 (2002) 1, 13-18, doi: 10.1016/S1359-6462(02)00089-1
15 Zichao L, Bin S, Fanghong S, Zhiming Z, Songshou G, Diamond-coated tube drawing die optimization using finite element model simulation and response surface methodology. Proceedings of the Institution of Mechanical Engineers Part B: Journal of Engineering Manufacture, 228 (2014) 11, 1432-1441, doi: 10.1177/0954405413518513
16 Feng Z, Niu W, Cheng C, Liao S, Hydropower system operation optimization by discrete differential dynamic programming based on orthogonal experiment design. Energy, (2017) 126, 720-732, doi: 10.1016/j.energy.2017.03.069
17 Jiaqiang E, Han D, Qiu A, Zhu H, Deng Y, Chen J, Zhao X, Zuo W, et al, Orthogonal experimental design of liquid-cooling structure on the cooling effect of a liquid-cooled battery thermal management system. Applied Thermal Engineering, (2018) 132, 508-520, doi: 10.1016/j.applthermaleng.2017.12.115
18 Chen S, Hong X, Harris C, Sparse kernel regression modeling using combined locally regularized orthogonal least squares and D-optimality experimental design. IEEE Transactions on Automatic Control, 48 (2003) 6, 1029-1036, doi: 10.1109/TAC.2003.812790
19 Kim S J, Cho Y G, Oh C S, Kim D E, Moon M B, Han H N, Development of a dual phase steel using orthogonal design method. Materials & Design, 30 (2009) 4, 1251-1257, doi: 10.1016/j.matdes.2008.06.017
20 Guan M, Hu Y, Zheng T, Zhao T, Pan F, Composition optimization and mechanical properties of Mg-Al-Sn-Mn alloys by orthogonal design. Materials, 11 (2018) 8, 1424, doi: 10.3390/ma11081424
21 Chen D, Huang J, Design of brass alloy drawing process using Taguchi method. Materials Science and Engineering: A, 464 (2007) 1-2, 135-140, doi: 10.1016/j.msea.2007.01.139
22 Harik G R, Lobo F G, Goldberg D E, The compact genetic algorithm. IEEE transactions on evolutionary computation, 3 (1999) 4, 287-297. doi: 10.1109/4235.797971
23 Hamdia K M, Zhuang X, Rabczuk T, An efficient optimization approach for designing machine learning models based on genetic algorithm. Neural Computing and Applications, 33 (2021) 6, 1923-1933, doi: 10.1007/s00521-020-05035-x
24 Kumar H, Manna R, Khan D, Evaluation of Johnson–Cook material model parameters for Fe–30Mn–9Al–0.8 C low-density steel in metal forming applications. Journal of Materials Science, 58 (2023) 19, 8118-8129, doi: 10.1007/s10853-023-08485-5
25 Saravanan R, Asokan P, Sachidanandam M, A multi-objective genetic algorithm (GA) approach for optimization of surface grinding operations. International journal of machine tools and manufacture, 42 (2002) 12, 1327-1334, doi: 10.1016/S0890-6955(02)00074-3
26 Wang Z, Sobey A, A comparative review between Genetic Algorithm use in composite optimisation and the state-of-the-art in evolutionary computation. Composite Structures, (2020) 233, 111739, doi: 10.1016/j.compstruct.2019.111739
27 Dehuri S, Mall R, Predictive and comprehensible rule discovery using a multi-objective genetic algorithm. Knowledge-Based Systems, 19 (2006) 6, 413-421, doi: 10.1016/j.knosys.2006.03.004
28 Pu L, Qi D, Xu L, Li Y, Optimization on the performance of ground heat exchangers for GSHP using Kriging model based on MOGA. Applied Thermal Engineering, (2017) 118, 480-489, doi: 10.1016/j.applthermaleng.2017.02.114
29 Sardinas R Q, Santana M R, Brindis E A, Genetic algorithm-based multi-objective optimization of cutting parameters in turning processes. Engineering Applications of Artificial Intelligence, 19 (2006) 2, 127-133, doi: 10.1016/j.engappai.2005.06.007
30 Li H, Xu B, Lu G, Du C, Huang N, Multi-objective optimization of PEM fuel cell by coupled significant variables recognition, surrogate models and a multi-objective genetic algorithm. Energy Conversion and Management, (2021) 236, 114063, doi: 10.1016/j.enconman.2021.114063
31 Chen X, He T, Huo Y, Du X, Zhang J, Li J, Zhang C, Simulation and experiment on equal channel angular drawing for 7075 aluminum alloy at room temperature. Forging & Stamping Technology, 48 (2023) 11, 67-72, doi: 10.13330/j.issn.1000-3940.2023.11.011
32 Ge M, Du C, Preparation process of shear thickening gel based on constrained uniform mixture design and orthogonal experimental design. Polymer Testing, (2023) 129, 108267, doi: 10.1016/j.polymertesting.2023.108267
33 Shrot A, Bäker M, Determination of Johnson–Cook parameters from machining simulations. Computational Materials Science, 52 (2012) 1, 298-304, doi: 10.1016/j.commatsci.2011.07.035
34 Iwahashi Y, Horita Z, Nemoto M, Wang J, Langdon T G, Principle of equal-channel angular pressing for the processing of ultra-fine grained materials. Scripta materialia, 35 (1996) 2, 143-146, doi: 10.1016/1359-6462(96)00107-8
35 Yang Y, Zhou L, Zhou H, Lv W, Wang J, Shi W, He Z, Optimal design of slit impeller for low specific speed centrifugal pump based on orthogonal test. Journal of Marine Science and Engineering, 9 (2021) 2, 121, doi: 10.3390/jmse9020121
36 Shuken S R, McNerney M W, Costs and benefits of popular P-value correction methods in three models of quantitative omic experiments. Analytical chemistry, 95 (2023) 5, 2732-2740, doi: 10.1021/acs.analchem.2c03719
Published
2025-06-11
How to Cite
1.
Zhu J, He T, Chen X, Du X, Vereschaka A, Li J, Deng S. OPTIMIZATION AND INFLUENCE OF PROCESS PARAMETERS ON ECAD SECTION SHRINKAGE OF 7075 Al ALLOY. MatTech [Internet]. 2025Jun.11 [cited 2026Aug.13];59(3):403–413. Available from: https://mater-tehnol.si/index.php/MatTech/article/view/1342
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