A novel multiscale material plasticity simulation model for high-performance cutting AISI 4140 steel

Abstract The achievable machined surface quality relies significantly on the material behavior during high-performance cutting process. In this paper, a multiscale plasticity simulation framework is developed to predict deformation behaviors of AISI 4140 steel under various conditions. was built by coupling three-dimensional discrete dislocation dynamic (3D-DDD) model with finite element method (FEM) through optimization density-based (DDB) constitutive equation (compiled as user-defined subroutine in ABAQUS). movement edge and screw dislocations such generation, propagation, siding, their interactions, performed 3D-DDD, statistical features were used optimize critical constants DDB equation. For validation, classic FEM (Johnson-Cook equation) employed reference. results indicated that proposed not only can precisely stress, strain, force, temperature those predicted simulations, but also capture microstructure characteristics grain size density distributions tested Severe recrystallization phenomena found at core shear zones. process reached equilibrium surfaces when speed larger than 280 m/min or external-assisted between 200 350°, indicating an optimal range machining parameters for improved integrity.