A microstructure sensitive grain boundary sliding and slip based constitutive model for machining of $\mathrm{Ti}$-$\mathrm{6Al}$-$\mathrm{4V}

We report a composite dual phase internal state variable constitutive model was developed for Ti-6Al-4V. The proposed model includes diffusion assisted grain boundary sliding based physics in addition to a traditional slip-based plasticity. Influence of microstructure on the flow stress is introduced via dislocation density and mean grain size internal state variables. The dislocation density evolves according to a physics based law that considers dislocation nucleation and annihilation processes. Grain refinement is driven by dynamic recrystallization, which is modeled phenomenologically. The model is calibrated with uniaxial stress–strain data that ranges between quasi-static and dynamic rates across a wide range of temperatures. Validation against machining data shows that the model predicts chip segmentation frequency, machining forces, and tool temperatures reasonably well. The newly introduced grain boundary sliding physics was found to dominate deformation following sufficient grain refinement. This deformation mode provides softening at the constitutive level without the need for invoking damage based softening mechanisms. This physical interpretation is something that has not previously been explored in the machining literature.