Abstract This paper presents a physics based Finite Element (FE) model to explore the microstructural phenomena occurring during severe plastic deformation processes, taking into account the influence of deformation-induced twinning, dislocation accumulation, and grain size evolution. In particular, the model was exploited to analyse the strengthening behaviour of Commercially Pure Titanium (CP-Ti) subjected to orthogonal cutting processes. Orthogonal cutting experiments were performed to validate the FE model in terms of cutting forces, chip morphology, microstructure, and workpiece surface hardness. The model is also used to analyse the individual contributions of dislocation accumulation, crystal twinning, and grain size refinement phenomena to material strengthening. The results show that dislocation accumulation and twinning are the main contributors to workpiece surface hardening in cutting of CP-Ti under the conditions studied in this work. Moreover, the model was employed to investigate additional cutting conditions, demonstrating a useful capability to improve the manufacturing process to obtain superior performance.

中文翻译：

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模拟商业纯钛正交微观和宏观切削中孪晶和位错诱导强化的影响

摘要 本文提出了一种基于物理的有限元 (FE) 模型，以探讨在严重塑性变形过程中发生的微观结构现象，同时考虑到变形诱导孪晶、位错积累和晶粒尺寸演变的影响。特别是，该模型被用来分析在正交切割过程中商业纯钛 (CP-Ti) 的强化行为。进行正交切削实验以在切削力、切屑形态、微观结构和工件表面硬度方面验证有限元模型。该模型还用于分析位错积累、晶体孪晶和晶粒细化现象对材料强化的个体贡献。结果表明，在本工作研究的条件下，位错积累和孪晶是导致 CP-Ti 切削过程中工件表面硬化的主要因素。此外，该模型还用于研究额外的切削条件，展示了改进制造工艺以获得卓越性能的有用能力。