3D finite element method (3D FEM) simulations of equal channel angular pressing (ECAP) and high-pressure torsion (HPT) of Al6061-T6 alloy were carried out and analyzed. 3D FEM results were correlated and compared with those obtained experimentally and theoretically through different mathematical equations. Furthermore, the hardness was estimated using the FEM strain and theoretical strain. The simulations and experimental results were in high conformity with each other. The ECAP load−displacement curves, the HPT load-time curves, and peak loads of FEM and experimental results were close to each other. FEM simulations provided clear strain distribution maps in different planes that fully explain the plastic deformation characteristics and homogeneity in the ECAP and HPT processes. FEM effective strain results have high reliability with a slight deviation from those theoretically estimated through the mathematical equations. The hardness distribution and the strain contours maps were in good agreement, confirming the quality of the FEM results. Hardness values calculated based on FEM effective strain indicate a deviation range of 0.96%–8.8% from experimental results that support the reliability of the FEM results. Microstructure results support hardness increase because of the effect of the grain refinement after ECAP and HPT processing.

对 Al6061-T6 合金的等通道角挤压 (ECAP) 和高压扭转 (HPT) 进行了 3D 有限元法 (3D FEM) 模拟和分析。将 3D FEM 结果与通过不同数学方程从实验和理论上获得的结果相关联并进行比较。此外，使用有限元应变和理论应变来估计硬度。模拟和实验结果高度一致。ECAP 载荷-位移曲线、HPT 载荷-时间曲线和 FEM 的峰值载荷与实验结果相互接近。FEM 模拟提供了不同平面中清晰的应变分布图，充分解释了 ECAP 和 HPT 过程中的塑性变形特征和均匀性。有限元有效应变结果具有较高的可靠性，与通过数学方程理论估计的结果略有偏差。硬度分布和应变等值线图非常吻合，证实了 FEM 结果的质量。基于 FEM 有效应变计算的硬度值表明与支持 FEM 结果可靠性的实验结果的偏差范围为 0.96%–8.8%。由于 ECAP 和 HPT 加工后晶粒细化的影响，显微组织结果支持硬度增加。96%–8.8% 来自支持 FEM 结果可靠性的实验结果。由于 ECAP 和 HPT 加工后晶粒细化的影响，显微组织结果支持硬度增加。96%–8.8% 来自支持 FEM 结果可靠性的实验结果。由于 ECAP 和 HPT 加工后晶粒细化的影响，显微组织结果支持硬度增加。