Finite Element Simulation Dataset for DTCAE Process

A modified advanced Severe Plastic Deformation (SPD) technique, termed Dual Twist Channel Angular Extrusion (DTCAE), is proposed as an alternative to Equal Channel Angular Pressing (ECAP) for producing ultrafine-grained (UFG) bulk alloys. The DTCAE die integrates a dual-twist mechanism, in which a 90° twist is applied to the billet before the 110° channel intersection, followed by a 45° reverse twist. A controlled extrusion zone at the exit further induces self-imposed back pressure through geometric constriction, thereby enhancing both strain magnitude and uniformity. Three-dimensional Finite Element Method (FEM) simulations using DEFORM-3D were employed to analyze plastic deformation and evaluate the effect of die geometry on strain distribution across different billet sections. The results reveal that DTCAE generates higher and more uniform strain compared to ECAP. Simulation outputs, including velocity vectors, effective strain contours, and load-stroke responses, confirm progressive and homogeneous deformation, demonstrating the effectiveness of the DTCAE process.