A modified Zerilli–Armstrong constitutive model for simulating severe plastic deformation of a steel alloy

A modified Zerilli–Armstrong model has been proposed and validated in previous works for simulating distinct deformation mechanisms of continuous-shear and shear-localization during severe plastic deformation of a face centered cubic alloy. In this paper, the validity of the modified Zerilli–Armstrong model has been further tested by using it for modeling the severe plastic deformation of another face centered cubic material, a steel alloy. In particular, the modified Zerilli–Armstrong model is used as a constitutive relation for simulating behavior of AISI 1045 steel alloy while undergoing severe plastic deformation through orthogonal and plane-strain machining. Accordingly, the performance of the constitutive relation in predicting flow stress distribution along the primary shear zone is validated by comparing with forecasts made using the distributed primary zone deformation, the original Zerilli-Armstrong and Johnson-Cook models. Furthermore, finite element simulations of orthogonal cutting of this steel alloy were carried out, and good agreement was observed between the predicted chip morphology and attendant cutting forces with experimental values reported in literature for a range of cutting conditions. The force predictions also fared better compared to those predicted by using the Zerilli-Armstrong and Johnson-Cook models. These validations provide further corroboration of using the modified Zerilli–Armstrong model as a constitutive relation for simulating the behavior of face-centered cubic materials under conditions of high plastic strains and also high strain-rates.