A multi-scale modelling by coupling cellular automata with finite element method and its application on cross-wedge rolling

Cross-wedge rolling is an advanced plastic forming process for manufacturing stepped-shafts. During the crosswedge rolling, the workpiece undergoes dynamic recrystallization, which has a significant effect on the grain refinement. A multiscale modelling method is required to predict and simulate the microstructure evolution. This work proposes a novel multi-scale modelling approach by coupling the cellular automata model and finite element method, which can visually simulate and predict the evolution and overall distribution of dynamic recrystallization microstructure. This novel multi-scale modelling method is verified by comparing the experimental results and simulation results of the microstructure of the uniaxial thermal compression test. The developed multi-scale modelling approach is applied to simulate the microstructure evolution and distribution of the high-speed railway axle formed by cross-wedge rolling. The simulation results show that cross-wedge rolling is a typical local forming process, and the microstructure of different regions has significant differences.