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The Parallel Tubular Channel Angular Pressing Process (PTCAP) has emerged as a promising method for refining the grain structure and enhancing the mechanical properties of metallic materials through severe plastic deformation. This study focuses on a comprehensive investigation of the PTCAP process, combining experimental and numerical analysis to gain insights into its underlying mechanisms. Experimental investigations involve processing a commercially pure copper tube using PTCAP under controlled conditions. In parallel, an explicit numerical analysis is developed using ABAQUS software to simulate the deformation behavior during PTCAP. The model incorporates material constitutive equations and accounts to describe the material response under high strain rates and large deformations. The research aims to investigate how multi-pass PTCAP affects hardness, strain homogeneity, and stress distribution. A comparison between the load punch from the experimental and FEM is conducted to validate the FEM results, and there is a good correlation between both. Hardness measurements are conducted at various stages to quantify the changes in material hardness resulting from the successive PTCAP passes. The hardness of the Cu tube increased by 63.45, 94.51, 103.98, and 105.64% after 1 to 4 passes, respectively.

In this article, the commercially pure Al–Cu bimetallic tube has been produced by the parallel tubular channel angular pressing (PTCAP) process. Also, the PTCAP process has been simulated via the finite element ABAQUS software. The influence of some parameters of the process, such as die angle, friction coefficient, displacement of the inner and outer layers, punch speed, and deformation ratio, has been investigated numerically. Then, the effect of ultrasonic vibrations applied in this process has also been studied. The simulation results show that each parameter affects the process, and exert vibrations leading to a decrease in the forming force. The forming force of the experimental process is obtained to compare with the force obtained from the simulated process. The experimental test results showed that the experiment and numerical process have an acceptable correlation with each other. [ABSTRACT FROM AUTHOR]