Microstructure-sensitive large-deformation model for thermomechanical processing simulations

Current computational mechanics methods lack coupling between remeshing and microstructure-sensitive models. However, this combination is necessary to consider microstructural evolution during large-deformation, thermomechanical forming operations. A model focused on improving microstructure prediction under forming operations through the advancement of remeshing capabilities integrated with crystal plasticity finite element (CPFE) is developed. To enable coupling between remeshing and a large deformation crystal plasticity model, the current 3D adaptivity (i.e., remeshing) capabilities in LS-DYNA were enhanced to be compatible with a CPFE model. These enhancements include developing remapping techniques that properly account for crystallographic texture evolution during deformation. The tech-niques used for mapping of microstructure-related variables differ from the smooth interpolation schemes typically used for mapping of other field variables such as stress or displacement. It is demon-strated that combining the nonlinear large deformation capabilities of LS-DYNA, microstructure-sensitive remapping, and a CPFE model yields a simulation framework capable of accurately predicting evolution of location-specific forged part microstructures and shear band formation. Greater microstructural accu-racy in large-deformation models can lead to improved strength, life, and manufacturing yield of light-weight forged parts. (c) 2021 Elsevier Ltd. All rights reserved.