Abstract
High temperature and severe deformation induced by the turning process of Ti-6Al-4V alloy will significantly impact the microstructure evolution of the chip and machined surface layer, thus significantly affecting the mechanical properties of the machined part. This study innovatively proposed a coupling simulation technology regarding finite element (FE) and cellular automata (CA) to simulate the microstructure evolution on macroscale and mesoscale, respectively, to improve the mechanical performance of the machined part. The modified Johnson and Cook (JC) constitutive model was used and its constitutive parameters were determined by combining an experimental method with an inverse identification methodology, to improve the precision of FE simulation. Based on the determined constitutive parameters, the Johnson-Mehl-Avrami-Kolmogorov (JMAK) models of dynamic recrystallization (DRX) were integrated into the FE model to investigate the distribution fields of grain size on macroscale. Afterward, the microstructure evolution on mesoscale was simulated successfully based on CA models of microstructure evolution and related input parameters obtained from the FE simulation. Orthogonal cutting experiments and corresponding tests adopting Electron Back Scattering Diffraction (EBSD), scanning electron microscopy (SEM) and metallographic microscope were performed to verify the credibility of FE and CA simulations. The results of the simulation and the experiments showed a reasonable consistency. The effects of cutting parameters on the grain size were analyzed through simulations and experiments. As indicated by the results, the degree of grain refinement occurring in the adiabatic shear band and machined surface layer increased with the increase in the cutting speed and the feed rate under the selected ranges of cutting parameters, whereas the effect mechanisms of the cutting speed and the feed rate were different, which could be conducive to selecting appropriate cutting parameters, so as to improve the mechanical properties of the machined part.
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