Modeling of large deformation frictional contact in powder compaction processes

In this paper, the computational aspects of large deformation frictional contact are presented in powder forming processes. The influence of powder–tool friction on the mechanical properties of the final product is investigated in pressing metal powders. A general formulation of continuum model is developed for frictional contact and the computational algorithm is presented for analyzing the phenomena. It is particularly concerned with the numerical modeling of frictional contact between a rigid tool and a deformable material. The finite element approach adopted is characterized by the use of penalty approach in which a plasticity theory of friction is incorporated to simulate sliding resistance at the powder–tool interface. The constitutive relations for friction are derived from a Coulomb friction law. The frictional contact formulation is performed within the framework of large FE deformation in order to predict the non-uniform relative density distribution during large deformation of powder die pressing. A double-surface cap plasticity model is employed together with the nonlinear contact friction behavior in numerical simulation of powder material. Finally, the numerical schemes are examined for efficiency and accuracy in modeling of several powder compaction processes.     

Two active plane finite element model in Mohr–Coulomb elastoplasticity

This paper presents the exact finite element formulation based on two active surface Mohr–Coulomb model. The formulae can be easily used in the existing finite element code. Numerical studies show that the results of two active surface model has some translation than that of the traditional one active surface model.     

Development of a finite element model of metal powder compaction process at elevated temperature

This paper presents the finite element modelling of metal powder compaction process at elevated temperature. In the modelling, the behaviour of powder is assumed to be rate independent thermo-elastoplastic material where the material constitutive laws are derived based on a continuum mechanics approach. The deformation process of metal powder has been described by a large displacement based finite element formulation. The Elliptical Cap yield model has been used to represent the deformation behaviour of the powder mass during the compaction process. This yield model was tested and found to be appropriate to represent the compaction process. The staggered-incremental-iterative solution strategy has been established to solve the non-linearity in the systems of equations. Some numerical simulation results were validated through experimentation, where a good agreement was found between the numerical simulation results and the experimental data.     

3D dynamic modeling of powder forming processes via a simple and efficient node-to-surface contact algorithm

In this paper, a simple and efficient contact algorithm is presented for the evaluation of density distribution in three-dimensional dynamic modeling of powder compaction processes. The contact node-to-surface algorithm is employed to impose the contact constraints in large deformation frictional contact, and the contact frictional slip is modified by the Coulomb friction law to simulate the frictional behavior between the rigid punch and the work-piece. The 3D nonlinear contact friction algorithm is employed together with a double-surface cap plasticity model within the framework of large finite element deformation in order to predict the non-uniform relative density distribution during the dynamic simulation of powder die-pressing. The accuracy and robustness of contact algorithm is verified by the impact analysis of two elastic rods, which is compared with the analytical solution. Finally, the performance of computational schemes is illustrated in dynamic modeling of a set of powder components.     

Analysis of a history-dependent frictional contact problem

We consider a mathematical model which describes the quasistatic contact between a viscoelastic body and a foundation. The material’s behaviour is modelled with a constitutive law with long memory. The contact is frictional and is modelled with normal compliance and memory term, associated to the Coulomb’s law of dry friction. We present the classical formulation of the problem, list the assumptions on the data and derive a variational formulation of the model. Then we prove the unique weak solvability of the problem. The proof is based on arguments of history-dependent variational inequalities. We also study the dependence of the weak solution with respect to the data and prove a convergence result.     

Formulation and survey of ALE method in nonlinear solid mechanics

This paper investigates the applicability and accuracy of existing formulation methods in general purpose finite element programs to the finite strain deformation problems. The basic shortcomings in using such programs in these applications are then pointed out and the need for a different type of formulation is discussed. An arbitrary Lagrangian-Eulerian (ALE) method is proposed and a concise survey of ALE formulation is given. A consistent and complete ALE formulation is derived from the virtual work equation transformed to arbitrary computational reference configurations. Differences between the proposed formulations and similar ones in the literature are discussed. The proposed formulation presents a general approach to ALE method. It includes load correction terms and is suitable for rate-dependent and rate-independent material constitutive law. The proposed formulation reduces to both updated Lagrangian and Eulerian formulations as special cases.     

Analysis and Numerical Approximation of a Contact Problem Involving Nonlinear Hencky-Type Materials with Nonlocal Coulomb’s Friction Law

A static frictional contact problem between an elasto-plastic body and a rigid foundation is considered. The material’s behavior is described by the nonlinear elastic constitutive Hencky’s law. The contact is modeled with the Signorini condition and a version of Coulomb’s law in which the coefficient of friction depends on the slip. The existence of a weak solution is proved by using Schauder’s fixed-point theorem combined with arguments of abstract variational inequalities. Afterward, a successive iteration technique, based on the Ka?anov method, to solve the problem numerically is proposed, and its convergence is established. Then, to improve the conditioning of the iterative problem, an appropriate Augmented Lagrangian formulation is used and that will lead us to Uzawa block relaxation method in every iteration. Finally, numerical experiments of two-dimensional test problems are carried out to illustrate the performance of the proposed algorithm.     

Numerical modeling of large strain behavior of polymeric crushable foams

This paper describes a constitutive law modeling isotropic polymeric foam materials. Focus has been placed on modeling the relative density dependency effect on polymeric foams subjected to large deformations using uniaxial and hydrostatic compressive hardening laws. The constitutive model is written in terms of the rotated Kirchhoff stress and of its conjugate logarithmic, or Hencky, strain measure. A numerical scheme for solving the constitutive model is described and implemented using both the finite element and the element-free Galerkin methods, in a Total Lagrangian finite strain framework. The imposition of the unilateral contact with friction and the essential boundary conditions are obtained by applying the Augmented Lagrangian method. Numerical examples are presented in order to attest the performance of the proposed constitutive model.     

Fixed point strategies for elastostatic frictional contact problems

Several fixed point strategies and Uzawa algorithms (for classical and augmented Lagrangian formulations) are presented to solve the unilateral contact problem with Coulomb friction. These methods are analysed, without introducing any regularization, and a theoretical comparison is performed. Thanks to a formalism coming from convex analysis, some new fixed point strategies are presented and compared with known methods. The analysis is first performed on continuous Tresca problem and then on the finite dimensional Coulomb problem derived from an arbitrary finite element method. Copyright © 2007 John Wiley & Sons, Ltd.     

Modeling of nonlinear viscoelastic contact problems with large deformations

Contact problems are one of the most important engineering problems. These problems become much more tedious when one of the contacting bodies behaves nonlinear viscoelasticity and large deformations. This paper presents an incremental-iterative finite element model for the analysis of two dimensional quasistatic frictionless contact problems. Nonlinear viscoelastic behavior and large deformations are considered. The Schapery’s single-integral creep model with stress-dependent properties is used for nonlinear viscoelasticity. The constitutive equations are transformed into an incremental form resulting in a recursive relationship. Thereby, the need to store the entire strain histories is eliminated, except that from the previous time increment. The updated Lagrangian formulation is used to model the material and geometrical nonlinearities. Also, the Lagrange multiplier method is adopted to enforce the contact constraints. The converged solution is obtained using the Newton–Raphson iterative technique. The developed model has been verified with the previously published works and found a good agreement with them. To demonstrate the efficient capability of the developed computational model, three contact problems with different nature are analyzed.     

Computational Excavation Analysis of a Single Cutting Tool using a Hypoplastic Constitutive Model

We propose a computational model for the numerical analysis of the dynamic interaction between a single excavation tool and the surrounding soil. An incremental non-linear (hypoplastic) constitutive model is employed to capture the complex response of soft soils. Large displacements and deformations are handled by an Updated Lagrangian formulation, the particle finite element method (PFEM). (© 2016 Wiley-VCH Verlag GmbH & Co. KGaA, Weinheim)     

A constitutive model for thermoplastic materials subjected to high strain rates

Reliable prediction of the behaviour of structures made from polymers is a topic under considerable investigation in engineering practice. Especially, if the structure is subjected to dynamic loading, constitutive models considering the mechanical behaviour properly are not available in commercial finite element codes yet. A constitutive model is derived including important phenomena like necking, strain rate dependency, unloading behaviour and damage. In particular, different yield surfaces in compression and tension and strain rate dependent failure, the latter with damage induced erosion, is taken into account. With the present formulation, standard verification tests can be simulated successfully. Also, an elastic damage model can be used to approximate the unloading behaviour of thermoplastics adequately. (© 2005 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim)     

Investigation of discrete stress distribution for dry powder compaction using Discrete Element Method and weighted Voronoi tesselation

Powder compaction of granular material plays a substantial role in the manufacturing process of ceramics industry and powder metallurgy industry. The compaction behaviour is ruled by granular flow and densification of deformable particles. Discrete element method (DEM) allows to investigate the powder compaction process numerically on the microscale by modeling the forces on the particle level and simulating the particle motion. Three-dimensional data about particle size distribution and spatial structure of the particle packing can be extracted from micro-computed tomography (µCT). An average stress tensor can be computed from DEM results, evaluating the contact forces and the distances from the particle center to the contact point with respect to an average cell volume. A weighted Voronoi tesselation of the polydisperse particle assembly is proposed for mapping a cell volume to each individual particle. With this approach all structural information of the particle system can be transferred from a discrete particle model to a heterogeneous volume model of micro-structure. Discrete stress distributions for uniaxial powder compaction are presented. (© 2017 Wiley-VCH Verlag GmbH & Co. KGaA, Weinheim)     

Linear and Nonlinear Finite Element Analysis of Active Composite Laminates

The paper presents a finite element concept for analysis of thin-walled active structures featuring fiber reinforced composite laminate as a passive structural material. The structure is rendered active by embedding piezoelectric material as a multifunctional material. A 9-node degenerated shell element based on the first order shear deformation theory is developed as a modelling tool capable of predicting the general behavior of the structure for controlling purposes. The von-Kármán type nonlinearities are considered. The solution strategy of the geometrical nonlinear analysis is based on the incremental approach using the updated Lagrangian formulation. Some numerical results are given to demonstrate the behavior of the element. (© 2005 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim)     

Estimation of temperature in rubber-like materials using non-linear finite element analysis based on strain history

A finite element procedure for hyper-elastic materials such as rubber has been developed to estimate the temperature rise during cyclic loading. The irreversible mechanical work developed in rubber has been used to determine the heat generation rate for carrying out thermal analysis. The evaluation of the heat energy is dependent on the strains. The finite element analysis assumes Green–Lagrangian strain displacement relations, Mooney–Rivlin strain energy density function for constitutive relationship, incremental equilibrium equations, and Total Lagrangian approach and the stress and strain of the rubber-like materials are evaluated using a degenerated shell element with assumed strain field technique, considering both material and geometric non-linearities. A transient heat conduction analysis has been carried out to estimate the temperature rise for different time steps in rubber-like materials using Galerkin's formulations. A numerical example is presented and the computed temperature values for various load steps agree closely with the experimental results reported in the literature.     

Unilateral Contact with Coulomb Friction and Uncertain Input Data

Abstract

A quasivariational inequality (QVI) in R ^d , d = 2, 3, with perturbed input data is solved by means of a worst scenario (anti-optimization) approach, using a stability result for the solution set of perturbed QVI-problems. The theory is applied to the dual finite element formulation of the Signorini problem with Coulomb friction and uncertain coefficients of stress-strain law, friction, and loading.     

Numerical Prediction of Macroscopic Material Failure

The aim of this contribution is the numerical determination of macroscopic material properties based on constitutive relationships characterising the microscale. A macroscopic failure criterion is computed using a three dimensional finite element formulation. The proposed finite element model implements the Strong Discontinuity Approach (SDA) in order to include the localised, fully nonlinear kinematics associated with the failure on the microscale. This numerical application exploits further the Enhanced–Assumed–Strain (EAS) concept to decompose additively the deformation gradient into a conforming part corresponding to a smooth deformation mapping and an enhanced part reflecting the final failure kinematics of the microscale. This finite element formulation is then used for the modelling of the microscale and for the discretisation of a representative volume element (RVE). The macroscopic material behaviour results from numerical computations of the RVE. (© 2006 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim)     

A simplified formulation of a plate/shell element for geometrically nonlinear analysis of moderately large deflections with small rotations

This paper presents a total Lagrangian formulation of a plate/shell element for geometrically nonlinear analysis with the assumption of moderately large deflections but small rotations. Mallet and Marcal's nonlinear stiffness matrices [N₁] and [N₂] are derived explicitly by the procedure suggested by Rajasekaran and Murray for a four-node parallelogram isoparametric element with bilinear interpolation functions and an orthotropic constitutive relationship. The performance of the element based on this simplified formulation has been tested through a number of examples. It is concluded that this element offers potential for geometrically nonlinear analysis of large-scale practical structures.