The evolution of grain size and component mechanical behaviour are fundamental aspects to analyse and control when manufacturing processes are considered. In this context, severe plastic deformation (SPD) processes, in which a high shear strain is imposed on the material, are recognized as the main techniques to achieve microstructural changes and material strengthening by the recrystallization, attracting both academic and industrial investigation activities. At the same time, nowadays, sustainable manufacturing design is one of the main responsibilities of the researchers looking at UN2030 agenda and the modern industrial paradigms. In this paper a new severe SPD process is proposed with the aim to steer manufacturing to fourth industrial revolution using some of Industry 4.0 pillars. In particular, additive manufacturing (AM) and numerical simulations were setup as controlling and monitoring techniques in manufacturing process of wires. Strengthening effect (yield and ultimate tensile strength, plasticity and hardness) and microstructural evolution (continuous dynamic recrystallization -CDRX-) due to severe plastic deformation were experimentally analysed and numerically investigated by an innovative finite element (FE) model able to validate the effectiveness of a properly modified process for ultra-fine aluminium alloy AA6101 wires production designed with the aim to avoid any post manufacturing costly thermal treatment. The study provides an accurate experimental study and numerical prediction of the thermo-mechanical and microstructural phenomena that occur during an advanced large plastic deformation process; it shows how the combination of smart manufacturing and simulations control represents the key to renew the traditional manufacturing methods in the perspective of the Industry 4.0, connecting and integrating the manufacturing process for the industrial evolution in production.

在考虑制造过程时，晶粒尺寸和部件机械行为的演变是分析和控制的基本方面。在这种情况下，对材料施加高剪切应变的严重塑性变形 (SPD) 过程被认为是通过再结晶实现微观结构变化和材料强化的主要技术，吸引了学术和工业研究活动。与此同时，如今，可持续制造设计是研究 UN2030 议程和现代工业范式的研究人员的主要职责之一。在本文中，提出了一种新的严重 SPD 工艺，旨在利用工业 4.0 的一些支柱将制造业引导至第四次工业革命。特别是，增材制造（AM）和数值模拟被设置为线材制造过程中的控制和监测技术。由于严重塑性变形的强化效应（屈服和极限抗拉强度、塑性和硬度）和微观结构演变（连续动态再结晶 -CDRX-）通过创新的有限元 (FE) 模型进行了实验分析和数值研究，能够验证一种经过适当改进的超细铝合金 AA6101 线材生产工艺，旨在避免任何制造后昂贵的热处理。该研究为高级大塑性变形过程中发生的热机械和微观结构现象提供了准确的实验研究和数值预测；