Computational thermo-mechanical process design by integrating crystal plasticity and phase field model

Abstract. An integrated model, merging the crystal plasticity finite element model (CPFEM) and the phase field model (PFM), is introduced for simulating the thermo-mechanical processing of ultra-low carbon steels. CPFEM serves as the mechanical simulation tool, forecasting deformation inconsistencies such as local stress concentration, inhomogeneous dislocation distribution, and shear bands. Meanwhile, PFM is utilized for predicting microstructural evolution, particularly nucleation and growth during heat treatments. To seamlessly integrate CPFEM and PFM, which are based on the finite element and finite difference methods respectively, an optimized coupling algorithm is utilized to avoid excessive computational cost. Importantly, a generalized strain energy release maximization model is integrated into the PFM, which leverages the analytical outcomes of CPFEM to predict the recrystallization texture of steels, factoring in multiple slip activities under mechanical loading conditions. The proposed model is applied to evaluate the anisotropy and formability of the thermo-mechanically processed ultra-low carbon steel through virtual mechanical experiments.