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<p>During high-speed machining, the microstructure evolution of the machined superficial layer, driven by intense thermo-mechanical coupling, exerts substantial effects on mechanical properties and fatigue strength. The absence of reliable predictive models for superalloys, particularly in engineering contexts, underscores the necessity for developing novel modeling approaches. In this work, a framework of cross-scale modeling is proposed for orthogonal cutting process of GH4169 to study the grain-scale plastic accommodation in the machined superficial layer, which consists of a macro-scale orthogonal cutting model based on Johnson-Cook constitutive equation, and a meso-scale representative volume element (RVE) model based on the crystal plasticity finite element method (CPFEM). The RVE model is developed based on the actual microstructure characteristics of the machined superficial layer, and outputs of the macro-scale cutting model are assigned to the boundary condition of RVE model. Then, the RVE model is used and microstructure evolution of machined superficial layer is simulated by developing a user subroutine based on CFFEM. Finally, validation of the RVE model results is conducted through orthogonal cutting experiments and scanning electron microscopy (SEM) analysis. Besides, it is found that the strain distribution of the machined superficial layer is uneven, which is different from the macro-scale simulation.</p>

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Cross-scale simulation of microstructure evolution during orthogonal cutting process based on crystal plasticity finite element method

  • 期刊论文

  • 发表日期：

    2026年1月5日

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  • Zhang Zhao,
  • Zhou Zishun,
  • Dang Jianing,
  • Luo Ming,
  • Wu Baohai

摘要

During high-speed machining, the microstructure evolution of the machined superficial layer, driven by intense thermo-mechanical coupling, exerts substantial effects on mechanical properties and fatigue strength. The absence of reliable predictive models for superalloys, particularly in engineering contexts, underscores the necessity for developing novel modeling approaches. In this work, a framework of cross-scale modeling is proposed for orthogonal cutting process of GH4169 to study the grain-scale plastic accommodation in the machined superficial layer, which consists of a macro-scale orthogonal cutting model based on Johnson-Cook constitutive equation, and a meso-scale representative volume element (RVE) model based on the crystal plasticity finite element method (CPFEM). The RVE model is developed based on the actual microstructure characteristics of the machined superficial layer, and outputs of the macro-scale cutting model are assigned to the boundary condition of RVE model. Then, the RVE model is used and microstructure evolution of machined superficial layer is simulated by developing a user subroutine based on CFFEM. Finally, validation of the RVE model results is conducted through orthogonal cutting experiments and scanning electron microscopy (SEM) analysis. Besides, it is found that the strain distribution of the machined superficial layer is uneven, which is different from the macro-scale simulation.