Grain Boundaries (GBs) disrupt the motion of dislocations and thereby affect the elasto-plastic deformation behavior of polycrystalline alloys. A majority of conventional polycrystal plasticity models represent GBs as sharp interfaces and do not incorporate GB micro-mechanics. In this work, a novel constitutive formulation for finitely thick GB region is developed which incorporates properties of all the adjoining grains. The GB model is based on penalizing the slip rate on the slip systems of single crystals in the GB region with an extra activation energy term. The energy penalty is based on minimizing the remnant dislocation line on GB for incoming and outgoing slip systems and evolves with slip accumulation. The size dependent elasto-plastic response of polycrystals is captured in this model by incorporating Geometrically Necessary Dislocations (GNDs) in addition to the Statistically Stored Dislocations (SSDs). The model has been implemented in a Crystal Plasticity Finite Element Method (CPFEM) code and applied to simulate the plane strain uni-axial tensile deformation of FCC polycrystals. The analyses show that the model is able to capture: (i) the single crystal response for a bicrystal with zero misorientation; and (ii) the dependence of Hall–Petch factor on misorientation. A normalized critical GB thickness value has also been derived which renders the macroscopic response insensitive to the GB region size. Polycrystal CPFEM simulations demonstrate that the model can capture the strain dependence of Hall–Petch factor reasonably well.
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