Robert Bischof

• This work deals with the simulation of the micro-cutting process of titanium. For this purpose, a suitable crystal-plastic material model is developed and efficient implemen- tations are investigated to simulate the micro-cutting process. Several challenges arise for the material model. On the one hand, the low symmetry hexagonal close-packed crystal structure of titanium has to be considered. On the other hand, large defor- mations and strains occur during the machining process. Another important part is the algorithm for the determination of the active slip systems, which has a significant influence on the stability of the simulation. In order to obtain a robust implemen- tation, different aspects, such as the algorithm for the determination of the active slip systems, the method for mesh separation between chip and workpiece as well as the hardening process are investigated, and different approaches are compared. The developed crystal-plastic material model and the selected implementations are first validated and investigated using illustrative examples. The presented simulations of the micro-cutting process show the influence of different machining parameters on the process. Finally, the influence of a real microstructure on the plastic deformation and the cutting force during the process is shown.