Modeling of flow stress size effect based on variation of dislocation substructure in micro-tension of pure nickel

Micro-forming is one promising technology for manufacturing micro metal parts. However, the traditional metal-forming theories fail to analyze the plastic deformation behavior in micro-scale due to the size effect arising from the part geometry scaling down from macro-scale to micro-scale. To reveal the mechanism of plastic deformation behavior size effect in micro-scale, the geometrical parameters and the induced variation of microstructure by them need to be integrated in the developed constitutive models considering the free surface effect. In this research, the variations of dislocation cell diameter with original grain size, strain and location (surface grain or inner grain) are derived according the previous research data. Then the overall flow stress of the micro specimen is determined by employing the surface layer model and the relationship between dislocation cell diameter and the flow stress. This new developed constitutive model considers the original grain size, geometrical dimension and strain simultaneously. The flow stresses in micro-tensile tests of thin sheets are compared with calculated results using the developed constitutive model. The calculated and experimental results match well. Thus the validity of the developed constitutive model is verified.