Simulation of orthogonal micro-cutting of FCC materials based on rate-dependent crystal plasticity finite element model

Micro-machining of face centered cubic (FCC) metallic materials is simulated via the theory of rate-dependent crystal plasticity. This approach accounts for slip systems and crystallographic orientations in its constitutive framework in order to accurately model the evolution of localized shear band formed during severe plastic deformation of crystalline materials. Through developing a user-defined subroutine in the ABAQUS/Explicit FE platform, the constitutive model is implemented and used to study the influence of workpiece crystallographic orientation on the cutting and thrust specific energies of the process. Due to the high rate of deformation, mechanical properties of texture can be strongly affected by activation mechanism of dislocation motion. Hence, the effects of strain rate and thermal softening are considered in the investigation. Simulations have been carried out for oxygen-free high conductivity copper (OFHC), and the effects of various parameters such as initial orientation angle of the texture on the prediction of localized deformation in the form of adiabatic shear bands are examined. The results delineate the efficiency of the model. Also, this procedure can be made applicable to calibration of force model in micro-milling process.