Crystal plasticity finite element simulations using discrete Fourier transforms
Al-Harbi, Hamad F.
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Crystallographic texture and its evolution are known to be major sources of anisotropy in polycrystalline metals. Highly simplified phenomenological models cannot usually provide reliable predictions of the materials anisotropy under complex deformation paths, and lack the fidelity needed to optimize the microstructure and mechanical properties during the production process. On the other hand, physics-based models such as crystal plasticity theories have demonstrated remarkable success in predicting the anisotropic mechanical response in polycrystalline metals and the evolution of underlying texture in finite plastic deformation. However, the integration of crystal plasticity models with finite element (FE) simulations tools (called CPFEM) is extremely computationally expensive, and has not been adopted broadly by the advanced materials development community. The current dissertation has mainly focused on addressing the challenges associated with integrating the recently developed spectral database approach with a commercial FE tool to permit computationally efficient simulations of heterogeneous deformations using crystal plasticity theories. More specifically, the spectral database approach to crystal plasticity solutions was successfully integrated with the implicit version of the FE package ABAQUS through a user materials subroutine, UMAT, to conduct more efficient CPFEM simulations on both fcc and bcc polycrystalline materials. It is observed that implementing the crystal plasticity spectral database in a FE code produced excellent predictions similar to the classical CPFEM, but at a significantly faster computational speed. Furthermore, an important application of the CPFEM for the extraction of crystal level plasticity parameters in multiphase materials has been demonstrated in this dissertation. More specifically, CPFEM along with a recently developed data analysis approach for spherical nanoindentation and Orientation Imaging Microscopy (OIM) have been used to extract the critical resolved shear stress of the ferrite phase in dual phase steels. This new methodology offers a novel efficient tool for the extraction of crystal level hardening parameters in any single or multiphase materials.