Equal channel angular pressing (ECAP) is a well-established method for grain refinement in metallic materials by large shear plastic deformation, being the most promising and effective severe plastic deformation (SPD) technique. ECAP is a discontinuous process, so the billet removal implies a new development of the procedure: the new sample pushes out the previous sample. In resuming the process the head and the tail ends of the work piece which becomes strongly distorted and receiving different amount of strain have to be removed. Due to the path difference in material flow between upper and lower region of the outlet channel, a non-uniform strain and stress distribution across the width of the workpiece leaving the plastic deformation zone (PDZ) is achieved. A successful ECAP requires surpassing two obstacles: the necessary load level which directly affects tools and a favorable stress distribution so the material withstanding the accumulated strain of repeated deformation. Under back pressure (BP), materials have shown to be able to withstand more passes. As soon as the billet passes the PDZ along the bisector plane of the two channels, the compressive mean stress changes to tensile (leading to crack initiation), while in the presence of BP, a negative (compressive) stress is applied during the process. In this paper a comparative tridimensional finite element analysis (FEA) is performed to evaluate the behavior of a difficult-to-work Al-Mg alloy depending on tools geometry and process parameters. The results in terms of load level and strain distribution show the influence of the punch geometry and BP on the material behavior.
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