Numerical modelling of size effects in micro-cutting of f.c.c. single crystal: Influence of strain gradients

A size effect is exhibited by metals in cutting processes at small scales: a nonlinear escalation the energy per unit volume with decrease thickness of uncut chip. To understand this phenomenon, numerical model orthogonal micro-cutting f.c.c. single-crystal copper was developed, and three different depths cut (0.8 μm, 1.4 μm 2.0 μm) were considered. Enhanced models crystal plasticity (EMCP) strain-gradient (EMSGCP) implemented ABAQUS/Explicit through VUMAT Fortran subroutine used. Obtained results compared experiments reported literature. The influence on deformation response material investigated extensively terms distribution field variables such as strain gradients, stresses, lattice rotations activity slip systems. crystallographic orientation also studied. It observed that size-effect phenomenon predicted more accurately EMSGCP theory, where polar dislocations evolving during found to affect it significantly.