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Finite Element Analysis of Friction Effect on Deformation Behavior of Copper Rods in a Modified C2S2 Process

The influence of friction on deformation behavior of copper rods during the continuous ECAP process (a modified C2S2 for the processing of rods and wires) was analyzed by using DEFORM-2D finite element method. The effect of friction on the stress and strain distribution, strain homogeneity and the torque-time curves was investigated. In the modified C2S2 process, the effective stress distributions are symmetrically concentrated on the shear plane, but there is an inadequate length of the plastic deformation zone. The effective strain shows a distorted fan shape in the shear deformation zone. As the friction factor increases the distorted fan shape tends to be normal and thinner, indicating that the bigger the friction factor, the more homogeneous the shear deformation. The effective strain is uniform across more than 70% thickness of the specimen. The assumed shear deformation is further divided into three stages, which can be explained by the torque-time curves.