3D finite element analysis and experimental validation of constrained groove pressing–cross route as an SPD process for sheet form metals

A new modification of constrained groove pressing (CGP) process named as constrained groove pressing–cross route (CGP-CR) was suggested for severe plastic deformation (SPD) of sheet form metals with great potential for fabricating high strength nanostructured sheets. This process is based on the conventional CGP process including some modifications. One pass of this process includes eight stages (four corrugation and four flattening) and involves 90° cross-rotation between each two stages. As a result of each CGP-CR pass, a strain magnitude of ∼2.32 is imparted to the sample. To simulate the process, finite element modeling (FEM) was carried out using three-dimensional finite element analysis ABAQUS/Explicit simulation. Strain and hardness distribution through the sheet after CGP-CR process at different stages were examined via FEM. Low-carbon steel sheet was utilized as the testing material and CGP-CR process imparted upon it up to two passes. Afterward, equivalent plastic strain was measured ∼4.64. Results show that the magnitude and uniformity of strain were different along three main directions of sheets: rolling (RD), transverse (TD), and normal directions (ND), at different stages of process. In addition, the results indicate that, for the CGP-CR’d sheets up to two passes, the magnitude and uniformity of hardness simulated via FEM were consistent with the experimental data.