Damage percolation during stretch flange forming of aluminum alloy sheet

A multi-scale finite element (FE)-damage percolation model was employed to simulate stretch flange forming of aluminum alloys AA5182 and AA5754. Material softening and strain gradients were captured using a Gurson-based FE model. FE results were then fed into the so-called damage percolation code, from which the damage development was modelled within measured microstructures. The formability of the stretch flange samples was predicted based upon the onset of catastrophic failure triggered by profuse void coalescence within the measured second-phase particle field. Damage development is quantified in terms of crack and void areal fractions, and compared to metallographic results obtained from interrupted stretch flange specimens. Parametric study is conducted on the effect of void nucleation strain in the prediction of formability of stretch flanges to “calibrate” proper nucleation strains for both alloys.     

Void interaction and coalescence in polymeric materials

Beyond pressure-sensitivity, plastic deformation of glassy polymers exhibits intrinsic softening followed by progressive rehardening at large strains. This highly nonlinear stress–strain behavior is captured by a constitutive model introduced in this work. In the first part of the paper, we focus on void growth and coalescence in an axisymmetric representative material volume consisting of a single large void and a population of discrete microvoids. Our study shows that microvoid cavitation, enhanced by strain softening, accelerates the process of void coalescence resulting in brittle-like failure at lowered stresses and strains. Pressure-sensitivity also reduces stress-carrying capacity as well as influences the strain for void coalescence; plastic dilatancy effects are relatively milder. In the second part of the paper, we introduce a population of discrete spherical voids within a three-dimensional computational model to study void growth and damage ahead of a crack front. Our studies reveal a distinctive change in the deformed void shape from oblate to prolate when strain softening is followed by high rehardening at large plastic strains. By contrast, an extended strain softening regime promotes oblacity and facilitates multiple void interaction and their cooperative growth over large distances ahead of the crack front. This multi-void failure mechanism is exacerbated by pressure-sensitivity.     

板材成型中的分叉和断裂及其空洞扩展效应

用平面应力有限元方法分析空洞模型以模拟一种双相钢板材在成型过程中所遇到的微空洞损伤,经试算可使模型的总体和局部的响应与已有的实验相一致,由此可提供描述该材料的损伤本构参数并研究局部剪切带和扩散型颈缩等分叉现象,临界应变值的分布形成了成型极限图中的下限曲线,当空洞模型的总体应力急剧下降或微裂纹开始出现,其相应的总体应变值提供了上限曲线。     

冲击载荷下混凝土材料的动态本构关系

利用改装的杆径为 74mm的直锥变截面式大尺寸Hopkinson压杆对混凝土材料进行冲击压缩实验 ,系统研究了混凝土的应变率硬化效应 ,采用一种新的方法损伤冻结法对混凝土材料在冲击载荷下的损伤软化效应进行了系统研究 ,给出了冲击载荷下混凝土的损伤演化方程 ;在对数据进行合理分析的基础上 ,结合粘弹性本构理论 ,得到混凝土材料的损伤型线性粘弹性本构关系。     

绝热剪切损伤和破坏的数值模拟研究

绝热剪切破坏是冲击载荷作用下金属材料中经常出现的一种重要破坏模式,尽管已经在实验中观察到了绝热剪切带内部的损伤现象,但是在理论和计算模型中往往还只是考虑它的热软化效应,对与之伴随的损伤破坏效应却鲜有讨论．该文在前人实验的基础上,提出了一个适用于绝热剪切带内部微孔洞损伤发展的演化方程,并在本构方程中同时考虑了温度和损伤对材料的影响,成功地模拟出了绝热剪切带的热软化效应和损伤破坏效应．     

A micromechanics based damage model for composite materials

The predictive capacity of ductile fracture models when applied to composite and multiphase materials is related to the accuracy of the estimated stress/strain level in the second phases or reinforcements, which defines the condition for damage nucleation. Second phase particles contribute to the overall hardening of the composite before void nucleation, as well as to its softening after their fracture or decohesion. If the volume fraction of reinforcement is larger than a couple of percents, this softening can significantly affect the resistance to plastic localization and cannot be neglected. In order to explicitly account for the effect of second phase particles on the ductile fracture process, this study integrates a damage model based on the Gologanu–Leblond–Devaux constitutive behavior with a mean-field homogenization scheme. Even though the model is more general, the present study focuses on elastic particles dispersed in an elasto-plastic matrix. After assessing the mean-field homogenization scheme through comparison with two-dimensional axisymmetric finite element calculations, an extensive parametric study is performed using the integrated homogenization-damage model. The predictions of the integrated homogenization-damage model are also compared with experimental results on cast aluminum alloys, in terms of both the fracture strain and overall stress–strain curves. The study demonstrates the complex couplings among the load transfer to second phase particles, their resistance to fracture, the void nucleation mode, and the overall ductility.     

Constitutive equations of a tensorial model for ductile damage of metals

Based on a micromechanical concept of void growth and change in void shape, a dissipation potential and constitutive equations for ductile damage of metals are presented. Multiplicative decomposition of the metric transformation tensor and thermodynamic formulation of the constitutive equations lead to a symmetric second-order tensor of damage which is physically meaningful. Its first invariant defines the damage related to plastic dilatation of the material due to the void growth. The second invariant of the deviatoric tensor accounts for the damage associated with a change in the void shape. Two physically motivated normalized measures allow us to represent the kinetic process of strain-induced damage by using the equivalent parameter of damage including the limit conditions for the onset of void coalescence and ductile failure. An experimental analysis of the evolution of ductile damage is presented for the case of uniaxial tension of sheet steel specimens with artificial defects.     

光滑圆柱拉伸试件的颈缩分析

对Gurson本构方程作了初步的研究，并对圆柱光滑拉伸试件在颈缩阶段用Gurson本构方程做了大应变弹塑性有限元分析。讨论了颈缩区空穴形核、扩张、静水应力以及材料软化的问题，初步揭示了空穴的演化过程和材料的破坏机理。有限元分析的结果表明，颈缩阶段空穴长大聚合机理非常显著，而形核作用相对较弱。     

A first-order strain gradient damage model for simulating quasi-brittle failure in porous elastic solids

In order to simulate quasi-brittle failure in porous elastic solids, a continuum damage model has been developed within the framework of strain gradient elasticity. An essential ingredient of the continuum damage model is the local strain energy density for pure elastic response as a function of the void volume fraction, the local strains and the strain gradients, respectively. The model adopts Griffith’s approach, widely used in linear elastic fracture mechanics, for predicting the onset and the evolution of damage due to evolving micro-cracks. The effect of those micro-cracks on the local material stiffness is taken into account by defining an effective void volume fraction. Thermodynamic considerations are used to specify the evolution of the latter. The principal features of the model are demonstrated by means of a one-dimensional example. Key aspects are discussed using analytical results and numerical simulations. Contrary to other continuum damage models with similar objectives, the model proposed here includes the effect of the internal length parameter on the onset of damage evolution. Furthermore, it is able to account for boundary layer effects.     

弹体攻角侵彻混凝土数值模拟

利用LS-DYNA程序的用户自定义模型功能,在LS-DYNA程序中嵌入了用于描述混凝土及钢筋混凝土侵彻贯穿的动态损伤模型。模型拉伸部分用Taylor-Chen-Kuszmaul(TCK)模型描述,体现了应变率对拉伸作用的敏感性;压缩部分则采用Holmquist-Johnson-Cook(HJC) 强度模型。模型中考虑了拉伸损伤、压缩损伤、应变软化、静水压力效应以及应变率效应。利用该方法对弹体攻角非正侵彻混凝土靶过程中的弹体变形、混凝土靶的损伤破坏、弹体的速度变化规律及弹体的变形进行了计算,并将计算结果与实验结果进行了比较,结果表明,采用该模型可以较好地模拟弹体非正侵彻混凝土过程。     

基于颗粒离散元法的连接键应变软化模型及其应用

基于颗粒间的有限接触假设,提出了可表述颗粒间力、力矩传递的连接键模型. 为了表征连接键的塑性、损伤及断裂过程,在连接键中引入了考虑应变软化效应的Mohr-Coulomb 准则及最大拉应力准则. 单一连接键的单向拉伸测试及直剪测试表明了上述连接键应变软化模型的计算精度. 研究了颗粒体系的宏观应变能与颗粒平均配位数的对应关系. 通过计算发现,对于二维颗粒体系,当平均配位数为5 时,颗粒体系的宏观应变能与相同参数下连续介质方法(如有限元等) 计算获得的应变能基本一致. 利用上述连接键应变软化模型对岩石的单轴压缩过程进行了模拟,计算结果表明:岩石单轴压缩的应力应变曲线经历了线性上升段、非线性上升段、非线性下降段及缓变段等4 个阶段,并给出了上述4 个阶段与岩石内部损伤破裂状态的内在联系. 计算结果还表明,随着断裂应变的增大,岩石的破裂模式逐渐由拉剪复合型破裂向单一压剪型破裂转化;随着断裂应变的增大,峰值应力及达到峰值应力时的应变均逐渐增大,但峰值时的破裂度及终态时的破裂度将逐渐减小.      

A constitutive model for elastoplastic solids containing primary and secondary voids

In many ductile metallic alloys, the damage process controlled by the growth and coalescence of primary voids nucleated on particles with a size varying typically between 1 and 100 μm, is affected by the growth of much smaller secondary voids nucleated on inclusions with a size varying typically between 0.1 and 3 μm. The goal of this work is first to quantify the potential effect of the growth of these secondary voids on the coalescence of primary voids using finite element (FE) unit cell calculations and second to formulate a new constitutive model incorporating this effect. The nucleation and growth of secondary voids do essentially not affect the growth of the primary voids but mainly accelerate the void coalescence process. The drop of the ductility caused by the presence of secondary voids increases if the nucleation strain decreases and/or if their volume fraction increases and/or if the primary voids are flat. A strong coupling is indeed observed between the shape of the primary voids and the growth of the second population enhancing the anisotropy of the ductility induced by void shape effects. The new micromechanics-based coalescence condition for internal necking introduces the softening induced by secondary voids growing in the ligament between two primary voids. The FE cell calculations were used to guide and assess the development of this model. The use of the coalescence condition relies on a closed-form model for estimating the evolution of the secondary voids in the vicinity of a primary cavity. This coalescence criterion is connected to an extended Gurson model for the first population including the effect of the void aspect ratio. With respect to classical models for single void population, this new constitutive model improves the predictive potential of damage constitutive models devoted to ductile metal while requiring only two new parameters, i.e. the initial porosity of second population and a void nucleation stress, without any additional adjustment.     

Effects of microscale inertia on dynamic ductile crack growth

The aim of this paper is to investigate the role of microscale inertia in dynamic ductile crack growth. A constitutive model for porous solids that accounts for dynamic effects due to void growth is proposed. The model has been implemented in a finite element code and simulations of crack growth in a notched bar and in an edge cracked specimen have been performed. Results are compared to predictions obtained via the Gurson–Tvergaard–Needleman (GTN) model where micro-inertia effects are not accounted for. It is found that microscale inertia has a significant influence on the crack growth. In particular, it is shown that micro-inertia plays an important role during the strain localisation process by impeding void growth. Therefore, the resulting damage accumulation occurs in a more progressive manner. For this reason, simulations based on the proposed modelling exhibit much less mesh sensitivity than those based on the viscoplastic GTN model. Microscale inertia is also found to lead to lower crack speeds. Effects of micro-inertia on fracture toughness are evaluated.     

脆性固体损伤和局部软化的有限元分析

本文研究混凝土、岩石一类工程中常用的应变软化材料的有限元分析方法。在作者以往有关粘塑性损伤本构模型的工作基础上，给出了一组便于有限元计算的本构方程表达式。包括损伤弹性矩阵和局部损伤软化矩阵，分别运用于计算硬化和软化阶段的有限元刚度矩阵；对所提出的本构方程的实验验证计算和一些算例的有限元数值分析，表明文中给出的本构方程是可行的，相应的有限元算法能较好地对损伤固体的局部软化效应进行数值分析，并可成功地追踪应力应变响应的软化曲线     

Experimental investigation and modelling of compressibility induced by damage in carbon black-reinforced natural rubber

While natural rubber is commonly considered as an incompressible material, this study shows how carbon black-reinforced natural rubber (NR-CB), when subjected to various mechanical loading conditions (uniaxial, hydrostatic, monotonic, cyclic), is affected by volume change. Experiments show a volume variation even for low straining values and a significant volume change for large elongations. Moreover, volume change can be either reversible or not, depending on the loading conditions. It is related to a competition between void growth, chain orientation, and stress softening. At a microscopic scale, in situ Scanning Electron Microscopy (SEM) examinations and image analysis allow one to record damage and microscopic volume change as a function of elongation. Therefore the volume change measured at the microscopic scale is equal to the macroscopic one. Based on the experimental results, this paper shows that the hypothesis of incompressibility is worth being revisited. Thus, a nearly compressible approach was considered, where the strain energy is assumed to be the sum of spherical and deviatoric parts that are both affected by damage. The model was then implemented in a finite-element code. Good agreement was obtained between experimental results and model predictions for low triaxiality test conditions.     

Void growth and interaction in crystalline materials

An inelastic rate-dependent crystalline constitutive formulation and specialized computational schemes have been developed and used to obtain a detailed understanding of the interrelated physical mechanisms that can result in ductile material failure in rate-dependent porous crystalline materials subjected to finite inelastic deformations. The effects of void growth and interaction and specimen necking on material failure have been investigated for a single material cell, with a discrete cluster of four voids, where geometrical parameters have been varied to result in seven unique periodic and random void arrangements. The interrelated effects of void distribution and geometry, strain hardening, geometrical softening, localized plastic strains and slip-rates, and hydrostatic stresses on failure paths and ligament damage in face centered cubic (f.c.c.) crystalline materials have been studied. Results from this study are consistent with experimental observations that ductile failure can occur either due to void growth parallel to the stress axis, which results in void coalescence normal to the stress axis, or void interaction along bands, which are characterized by intense shear-strain localization and that intersect the free surface at regions of extensive specimen necking.     

Review of theoretical models of the strain-based FLD and their relevance to the stress-based FLD

The forming limit diagram (FLD) is used in sheet metal forming analysis to determine how close the sheet metal is to tearing when it is formed into a product shape in a stamping process. The strain-path dependent nature of the FLD causes the method to become ineffective in the analysis of complex forming process, especially restrikes, flanging operations, hydroforming, and even first draw dies with deep pockets or embossments. Experimental evidence for a path-independent stress-based FLD has been reported in the literature, suggesting that the path dependency of the strain-based approach arises from the path dependent constitutive laws governing the relationship between the stress and strain tensors. This paper reviews several theoretical models of sheet metal forming instability, including bifurcation analyses of diffuse and through-thickness neck formation, the M-K model and microscopic void damage models. The equations governing the deformation at the instant of the bifurcation is shown to be independent of path in all of these models, providing a solid theoretical bases for the stress-based approach. The stress-based FLD can now be used equally well for all forming processes, without concern for path effects.     

微孔洞生长对板材拉伸过程中变形局部化的影响

本文在作者提出的含孔洞材料下限本构方程的基础上，采用了初始缺陷带模型对微孔洞生长及分布对板材拉伸过程中变形局部影响进行了，分析着重研究了细观损演化规律对变形局部化模式及临界应变的影响，并成功预测了ＡＩＳＩ４３４０钢板材拉伸试件变形局部化换稳为及失稳方向。