Analysis of Large-Strain Extrusion Machining with Different Chip Compression Ratios

Large-Strain Extrusion Machining (LSEM) is a novel-introduced process for deforming materials to very high plastic strains to produce ultra-fine nanostructured materials. Before the technique can be exploited, it is important to understand the deformation behavior of the workpiece and its relationship to the machining parameters and friction conditions. This paper reports finite-element method (FEM) analysis of the LSEM process to understand the evolution of temperature field, effective strain, and strain rate under different chip compression ratios. The cutting and thrust forces are also analyzed with respect to time. The results show that LSEM can produce very high strains by changing in the value of chip compression ratio, thereby enabling the production of nanostructured materials. The shape of the chip produced by LSEM can also be geometrically well constrained.