Crystal plasticity model of induction heating-assisted incremental sheet forming with recrystallisation simulation in cellular automata

Abstract To relate the thermomechanical behaviour and microstructural evolution of the heat-assisted incremental sheet forming (SPIF) for Ti–6Al–4 V sheet, multi-scale models based on crystal plasticity finite element model (CPFEM), representative elementary volume (RVE), and cellular automaton (CA) were established in this article. An experimental-scale CPFEM was built in advance to provide macrograin level strain, strain rate, and temperature output data, which were then used in RVE and CA as inputs to simulate the microstructural evolution throughout the SPIF process. The output results include the pole figures, dynamic recrystallisation (DRX) maps, and statistics results of the alpha (α) phase of the Ti–6Al–4 V (α-Ti) alloy from stage to stage throughout the 700 $$^\circ{\rm C}$$ ∘ C SPIF. The obtained statistics results of dislocation density, grain orientation angles, and grain size were verified with electron backscatter diffraction (EBSD). The CA analysis of the DRX progress at the upper, centre, and lower regions of the deformed workpiece has discovered that the incremental increase of the strain rate has significant effects on the dislocation density that produced a proportional relationship to the DRX percentage. The results revealed that the strain rate has strong domination in affecting the slip of grains orientation, which overcomes the effect of temperature increase in this SPIF process. Furthermore, it was found that a large amount of DRXed grains were generated at the grain boundaries, which reduced the mean grain size and increased the DRX percentage, which produced an inversely proportional relationship to the dislocation density. The thermomechanical behaviour on the SPIF workpiece was increased incrementally, which is insufficient for DRX initiation in the upper region, and the behaviour was enhanced at the centre and lower region, which can be corresponded to the microstructural evolution throughout the process.