Equal channel angular pressing (ECAP) is an attractive process method to produce bulk ultra-fine grained materials. There are many experiment evidences showing that the nature of the microstructural evolution in multi-pass ECAP depends on process routes. Isothermal three dimensional FEM simulations for multi-pass ECAP were performed using DEFORM3D finite element code. The material model of 6061Al-T6 was employed. Flow nets, effective strain distribution in the workpiece and loads during multi-pass ECAP using different routes were analysed respectively. The simulations show process routes influence material flow and effective strain distribution in the workpiece obviously but have few influence on loads.
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