The behaviour of metals and alloys during thermomechanical processing is significantly affected by the microstructure-property relationship and microstructure evolution. Tailoring the material and the process conditions is important to achieve the desired properties of the product for its particular application. On the other hand, by choosing appropriate process conditions, formability can be improved and forming force as well as energy consumption can be reduced. The development of tailored materials and manufacturing processes can be efficiently supported by simulations that quantitatively predict the coupling between the thermomechanical material behaviour and microstructure evolution.
For simulating manufacturing processes of metallic materials, we propose a model taking the strong coupling between elastoplastic deformation, recovery, recrystallization, grain coarsening and the related thermal effects into account. For the microstructure description, we use a mean-field approach representing grains and second phase precipitates. In order to guarantee consistency with fundamental physical principles, the model is derived from a comprehensive thermodynamic framework.
The process model is numerically implemented as a standalone simulation tool. We demonstrate its capability to consistently predict the interplay between elastoplastic deformation, microstructure evolution, dynamic hardening and softening and the related temperature change. The numerical examples comprise simple thermomechanical tests as well as a realistic manufacturing process chain.