A novel yield function for single crystals based on combined constraints optimization

A novel yield function representing the overall plastic deformation in a single crystal is developed using the concept of optimization. Based on the principle of maximum dissipation during a plastic deformation, the problem of single crystal plasticity is first considered as a constrained optimization problem in which constraints are yield functions for slip systems. To overcome the singularity that usually arises in solving the above problem, a mathematical technique is used to replace the above constrained optimization problem with an equivalent problem which has only one constraint. This single constraint optimization problem, the so-called combined constraints crystal plasticity (CCCP) model, is implemented into a finite element code and the results of modeling the uniaxial tensions of the single crystal copper along different crystallographic directions and also hydroforming of aluminum tubes proved the capability of the proposed CCCP model in accurately predicting the deformation in polycrystalline materials.     

Forming simulation of aluminum sheets using an anisotropic yield function coupled with crystal plasticity theory

This paper describes the application of a coupled crystal plasticity based microstructural model with an anisotropic yield criterion to compute a 3D yield surface of a textured aluminum sheet (continuous cast AA5754 aluminum sheet). Both the in-plane and out-of-plane deformation characteristics of the sheet material have been generated from the measured initial texture and the uniaxial tensile curve along the rolling direction of the sheet by employing a rate-dependent crystal plasticity model. It is shown that the stress–strain curves and R-value distribution in all orientations of the sheet surface can be modeled accurately by crystal plasticity if a “finite element per grain” unit cell model is used that accounts for non-uniform deformation as well as grain interactions. In particular, the polycrystal calculation using the Bassani and Wu (1991) single crystal hardening law and experimental electron backscatter data as input has been shown to be accurate enough to substitute experimental data by crystal plasticity data for calibration of macroscopic yield functions. The macroscopic anisotropic yield criterion CPB06ex2 (Plunkett et al., 2008) has been calibrated using the results of the polycrystal calculations and the experimental data from mechanical tests. The coupled model is validated by comparing its predictions with the anisotropy in the experimental yield stress ratio and strain ratios at 15% tensile deformation. The biaxial section of the 3D yield surface calculated directly by crystal plasticity model and that predicted by the phenomenological model calibrated with experimental and crystal plasticity data are also compared. The good agreement shows the strength of the approach. Although in this paper, the Plunkett et al. (2008) yield function is used, the proposed methodology is general and can be applied to any yield function. The results presented here represent a robust demonstration of implementing microscale crystal plasticity simulation with measured texture data and hardening laws in macroscale yield criterion simulations in an accurate manner.     

Characterization of yielding behavior of polycrystalline metals with single crystal plasticity based on representative characteristic length

Single crystal plasticity based on a representative characteristic length is proposed and introduced into a homogenization approach based on finite element analyses, which are applied to characterization of distinctive yielding behaviors of polycrystalline metals, yield-point elongation, and grain size strengthening. The computational manner for an implicit stress update is derived with the framework of a standard multi-surface plasticity at finite strain, where the evolution of the characteristic lengths are numerically converted from the accumulated slips of all of slip systems by exploiting the mathematical feature of the characteristic length as the intermediate function of the plastic internal variables. Furthermore, a constitutive model for a single crystal reproduces the stress–strain curve divided into three parts. Using two-scale finite element analysis, the macroscopic stress–strain response with yield-point elongation under a situation of low dislocation density is reproduced. Finally, the grain size effect on the yield strength is analyzed with modeling of the grain boundary in the context of the proposed constitutive model and is discussed from both macroscopic and microscopic views.     

Energetic dislocation interactions and thermodynamical aspects of strain gradient crystal plasticity theories

This paper focuses on the unification of two frequently used and apparently different strain gradient crystal plasticity frameworks: (i) the physically motivated strain gradient crystal plasticity models proposed by Evers et al. [2004a. Non-local crystal plasticity model with intrinsic SSD and GND effects. Journal of the Mechanics and Physics of Solids 52, 2379-2401; 2004b. Scale dependent crystal plasticity framework with dislocation density and grain boundary effects. International Journal of Solids and Structures 41, 5209-5230] and Bayley et al. [2006. A comparison of dislocation induced back stress formulations in strain gradient crystal plasticity. International Journal of Solids and Structure 43, 7268-7286; 2007. A three dimensional dislocation field crystal plasticity approach applied to miniaturized structures. Philosophical Magazine 87, 1361-1378] (here referred to as Evers-Bayley type models), where a physical back stress plays the most important role and which are further extended here to deal with truly large deformations, and (ii) the thermodynamically consistent strain gradient crystal plasticity model of Gurtin (2002-2008) (here referred to as the Gurtin type model), where the energetic part of a higher order micro-stress is derived from a non-standard free energy function. The energetic micro-stress vectors for the Gurtin type models are extracted from the definition of the back stresses of the improved Evers-Bayley type models. The possible defect energy forms that yield the derived physically based micro-stresses are discussed. The duality of both type of formulations is shown further by a comparison of the micro-boundary conditions. As a result, this paper provides a direct physical interpretation of the different terms present in Gurtin's model.     

A multi-scale computational model of crystal plasticity at submicron-to-nanometer scales

Plastic flow in crystal at submicron-to-nanometer scales involves many new interesting problems. In this paper, a unified computational model which directly combines 3D discrete dislocation dynamics (DDD) and continuum mechanics is developed to investigate the plastic behaviors at these scales. In this model, the discrete dislocation plasticity in a finite crystal is solved under a completed continuum mechanics framework: (1) an initial internal stress field is introduced to represent the preexisting stationary dislocations in the crystal; (2) the external boundary condition is handled by finite element method spontaneously; and (3) the constitutive relationship is based on the finite deformation theory of crystal plasticity, but the discrete plastic strains induced by the slip of the newly nucleated or propagating dislocations are calculated by dislocation dynamics methodology instead of phenomenological evolution equations used in conventional crystal plasticity. These discrete plastic strains are then localized to the continuum material points by a Burgers vector density function proposed by us. Various processes, such as loop dislocation evolution, dislocation junction formation etc., are simulated to verify the reliability of this computational model. Specifically, a uniaxial compression test for micro-pillars of Cu is simulated by this model to investigate the ‘dislocation starvation hardening’ observed in the recent experiment.     

A physically based model of temperature and strain rate dependent yield in BCC metals: Implementation into crystal plasticity

In this work, we develop a crystal plasticity finite element model (CP-FEM) that constitutively captures the temperature and strain rate dependent flow stresses in pure BCC refractory metals. This model is based on the kink-pair theory developed by Seeger (1981) and is calibrated to available data from single crystal experiments to produce accurate and convenient constitutive laws that are implemented into a BCC crystal plasticity model. The model is then used to predict temperature and strain rate dependent yield stresses of single and polycrystal BCC refractory metals (molybdenum, tantalum, tungsten and niobium) and compared with existing experimental data. To connect to larger length scales, classical continuum-scale constitutive models are fit to the CP-FEM predictions of polycrystal yield stresses. The results produced by this model, based on kink-pair theory and with origins in dislocation mechanics, show excellent agreement with the Mechanical Threshold Stress (MTS) model for temperature and strain-rate dependent flow. This framework provides a method to bridge multiple length scales in modeling the deformation of BCC metals.     

Computationally efficient database and spectral interpolation for fully plastic Taylor-type crystal plasticity calculations of face-centered cubic polycrystals

A new computationally efficient database approach to fully plastic Taylor-type crystal plasticity calculations is presented in this paper. In particular, we explore strategies that circumvent the need to repeatedly solve sets of highly non-linear, extremely stiff, algebraic equations with poor convergence characteristics that are inherent to these calculations. The suggested strategies consist of computing only once all of the needed variables in crystal plasticity calculations, storing them, and retrieving the values of interest according to the need in any specific simulation. An algorithm is presented here that facilitates this approach, and involves local spectral interpolation using discrete fourier transform (DFT) methods. The approach described here results in major improvements in the computational time over both the conventional crystal plasticity calculations and our previously developed spectral approach using generalized spherical harmonics (GSH). Details of this new approach are described and validated in this paper through a few example case studies.     

Continuum thermodynamic models for crystal plasticity including the effects of geometrically-necessary dislocations

The purpose of this work is the formulation of constitutive models for the inelastic material behaviour of single crystals and polycrystals in which geometrically necessary dislocations (GNDs) may develop and influence this behaviour. To this end, we focus on the dependence of the development of such dislocations on the inhomogeneity of the inelastic deformation in the material. More precisely, in the crystal plasticity context, this is a relation between the density of GNDs and the inhomogeneity of inelastic deformation in glide systems. In this work, two models for GND density and its evolution, i.e., a glide-system-based model, and a continuum model, are formulated and investigated. As it turns out, the former of these is consistent with the original two-dimensional GND model of Ashby (Philos. Mag. 21 (1970) 399), and the latter with the more recent model of Dai and Parks (Proceedings of Plasticity ’97, Neat Press, 1997, p. 17). Since both models involve a dependence of the inelastic state of a material point on the (history of the) inhomogeneity of the glide-system inelastic deformation, their incorporation into crystal plasticity modelling necessarily implies a corresponding non-local generalization of this modelling. As it turns out, a natural quantity on which to base such a non-local continuum thermodynamic generalization, i.e., in the context of crystal plasticity, is the glide-system (scalar) slip deformation. In particular, this is accomplished here by treating each such slip deformation as either (1), a generalized “gradient” internal variable, or (2), as a scalar internal degree-of-freedom. Both of these approaches yield a corresponding generalized Ginzburg-Landau- or Cahn-Allen-type field relation for this scalar deformation determined in part by the dependence of the free energy on the dislocation state in the material. In the last part of the work, attention is focused on specific models for the free energy and its dependence on this state. After summarizing and briefly discussing the initial-boundary-value problem resulting from the current approach as well as its algorithmic form suitable for numerical implementation, the work ends with a discussion of additional aspects of the formulation, and in particular the connection of the approach to GND modelling taken here with other approaches.     

Dislocation-based micropolar single crystal plasticity: Comparison of multi- and single criterion theories

Two new formulations of micropolar single crystal plasticity are presented within a geometrically linear setting. The construction of yield criteria and flow rules for generalized continuum theories with higher-order stresses can be done in one of two ways: (i) a single criterion can be introduced in terms of a combined equivalent stress and inelastic rate or (ii) or individual criteria can be specified for each conjugate stress/inelastic kinematic rate pair, a so-called multi-criterion theory. Both single and multi-criterion theories are developed and discussed within the context of dislocation-based constitutive models. Parallels and distinctions are made between the proposed theories and some of the alternative generalized crystal plasticity models that can be found in the literature. Parametric numerical simulations of a constrained thin film subjected to simple shear are conducted via finite element analysis using a simplified 2-D version of the fully 3-D theory to highlight the influence of specific model components on the resulting deformation under both loading and unloading conditions. The deformation behavior is quantified in terms of the average stress-strain response and the local shear strain and geometrically necessary dislocation density distributions. It is demonstrated that micropolar single crystal plasticity can qualitatively capture the same range of behaviors as slip gradient-based models, while offering a simpler numerical implementation and without introducing plastic slip rates as generalized traction-conjugate velocities subject to an additional microforce balance.     

On the continuum thermodynamic rate variational formulation of models for extended crystal plasticity at large deformation

The purpose of this work is the unified formulation and generalization of selected models for extended, gradient, or “higher-order” crystal plasticity via the application of a recently developed rate variational approach to the formulation of continuum thermodynamic models for history-dependent, inelastic systems. The investigation here includes models which were not originally formulated in a thermodynamic or “work-conjugate” fashion. The approach is based on the formulation of rate potentials for each model whose form is determined by (i) energetic processes via the free energy, (ii) kinetic processes via the dissipation potential, and (iii) the form of the evolution relations for the internal-variable-like quantities upon which the free energy and dissipation potential depend. For the case of extended crystal plasticity, these latter quantities include for example the inelastic local deformation, or dislocation densities. The stationarity conditions of the corresponding rate functional then yield volumetric and surficial balance-like field relations determining in the current context for example the form of momentum balance or that of the generalized glide-system flow rule. With the help of this approach, we derive thermodynamically consistent forms of specific models for extended crystal plasticity. Since most of these were formulated for small deformation, we also investigate their generalization to large deformation with the help of, e.g., form invariance. Among other things, the current rate variational approach implies that, beyond the form of the free energy itself, it is form of the evolution relations for the dislocation densities which is important in determining whether or not higher-order model quantities like the glide-system back stress can be formulated in a thermodynamic fashion.     

Inspection of free energy functions in gradient crystal plasticity

The dislocation density tensor computed as the cud of plastic distortion is regarded as a new constitutive variable in crystal plasticity. The dependence of the free energy function on the dislocation density tensor is explored starting from a quadratic ansatz. Rank one and logarithmic dependencies are then envisaged based on considerations from the statistical theory of dislocations. The rele- vance of the presented free energy potentials is evaluated from the corresponding analytical solutions of the periodic two-phase laminate problem under shear where one layer is a single crystal material undergoing single slip and the second one remains purely elastic.     

Size effects in generalised continuum crystal plasticity for two-phase laminates

The solutions of a boundary value problem are explored for various classes of generalised crystal plasticity models including Cosserat, strain gradient and micromorphic crystal plasticity. The considered microstructure consists of a two-phase laminate containing a purely elastic and an elasto-plastic phase undergoing single or double slip. The local distributions of plastic slip, lattice rotation and stresses are derived when the microstructure is subjected to simple shear. The arising size effects are characterised by the overall extra back stress component resulting from the action of higher order stresses, a characteristic length l_c describing the size-dependent domain of material response, and by the corresponding scaling law lⁿ as a function of microstructural length scale, l. Explicit relations for these quantities are derived and compared for the different models. The conditions at the interface between the elastic and elasto-plastic phases are shown to play a major role in the solution. A range of material parameters is shown to exist for which the Cosserat and micromorphic approaches exhibit the same behaviour. The models display in general significantly different asymptotic regimes for small microstructural length scales. Scaling power laws with the exponent continuously ranging from 0 to −2 are obtained depending on the values of the material parameters. The unusual exponent value −2 is obtained for the strain gradient plasticity model, denoted “curl H^p” in this work. These results provide guidelines for the identification of higher order material parameters of crystal plasticity models from experimental data, such as precipitate size effects in precipitate strengthened alloys.     

Studies of scale dependent crystal viscoplasticity models

A scale dependent crystal viscoplasticity model with a second strain gradient effect is introduced, as a simple extension of the conventional crystal plasticity theory. We confine attention to a single crystal undergoing slip on a single slip system under small strain conditions. Connections between this model and other existing theories are investigated in some detail. Furthermore, some basic predictions of the model, due to the second gradients and the material viscosity, are illustrated, using a constrained simple shear problem for a thin strip bounded by two rigid walls. The effect of viscosity on evolution of the boundary layer is examined, as well as the behavior of the thin strip undergoing reverse/cyclic shear loading, and the ability to predict plastic flow localization.     

Multiscale modeling of irradiated polycrystalline FCC metals

We propose a set of models for the post-irradiation deformation response of polycrystalline FCC metals. First, a defect- and dislocation-density based evolution model is developed to capture the features of irradiation-induced hardening as well as intra-granular softening. The proposed hardening model is incorporated within a rate-independent single crystal plasticity model. The result is a non-homogeneous deformation model that accounts for defect absorption on the active slip planes during plastic loading. The macroscopic non-linear constitutive response of the polycrystalline aggregate of the single crystal grains is then obtained using a micro–macro transition scheme, which is realized within a Jacobian-free multiscale method (JFMM). The Jacobian-free approach circumvents explicit computation of the tangent matrix at the macroscale by using a Newton–Krylov process. This has a major advantage in terms of storage requirements and computational cost over existing approaches based on homogenized material coefficients in which explicit Jacobian computation is required at every Newton step. The mechanical response of neutron-irradiated single and polycrystalline OFHC copper is studied and it is shown to capture experimentally observed grain-level phenomena.     

A stochastic approach to capture crystal plasticity

A stochastic crystal plasticity model is proposed and applied within the rate-independent regime. As opposed to conventional deterministic algorithms wherein multiple slip systems are activated and redundant constraints may exist, the new Monte Carlo plasticity (MCP) paradigm is based on a stochastic chain of singly activated slip systems and thus avoids the possible ill-condition associated with multi-slip algorithms. The choice of the activated slip system is made at each Monte Carlo (MC) step based on the Metropolis algorithm. The MCP model is implemented within a Material Point Method (MPM) as a constitutive model to capture the elasto-plastic behavior of polycrystalline materials. A comparison with a commonly used singular value decomposition (SVD) algorithm indicates that MCP offers superior computational efficiency while maintaining comparable accuracy.     

Mesoscale plastic flow generation and development for polycrystals

The traditional yield criteria of plasticity such as Mises, Tresca, etc. make use of averaged macroparameters while mesomechanics consideration is based on the physical notion of plastic deformation mechanisms. They may involve the development of plastic shears on the surfaces and interfaces of internal structure elements involving stress concentration and relaxation. A criterion of plastic flow is proposed; it is based on the stress–strain state in a cell of computational grid as well as in the neighboring cells. An algorithm of plastic shear generation is developed for the progressive propagation of the plastic shears over the crystal. Test calculations of the crystal behavior under tension are made and the results are presented.     

Interpretation of the behavior of metals under large plastic shear deformations: comparison of macroscopic predictions to physically based predictions

A large plastic shear problem is analyzed by application of a macroscopic anisotropic plasticity model (Kuroda, M., 1997. Interpretation of the behavior of metals under large plastic shear deformations: a macroscopic approach. Int. J. Plasticity 13, 359–383), and the results are compared to predictions based on crystal plasticity with the Taylor assumption. It is found that these two different-scale models provide very similar predictions. The interpretations for such similarities are pursued in detail. The present macroscopic model reproduces quite well the change in orientation of anisotropy, which is directly predicted in the crystal plasticity analyses as a macroscopic manifestation of texture development. Consequently, the predictions for the rotation of the yield surface by the different-scale models become very similar. It is clearly shown that, in a macroscopic sense, the rotation of the anisotropic yield surface is a main cause of the axial effects in large plastic shear deformation.