Two-Dimensional finite element analysis was carried out to optimize the equal channel angular pressing process (ECAP) for strain homogeneity under frictionless and frictional conditions. The effect of outside corner angle (Ψ), inner radius (r) and shear friction (m) on the strain homogeneity was investigated. The strain homogeneity can be increased by correcting the outside corner to eliminate the corner gap between the sample and the die at the expense of average strain. Small inside radius and outside corner radius would provide large deformations without much loss in the strain homogeneity under frictionless conditions. The work piece deformation is by bending if the inner radius exceeds a critical value. No improvement in strain homogeneity was observed under frictional conditions.
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