高强钢及软钢断裂失效行为表征与仿真预测

针对汽车碰撞、结构强度等分析中无法准确模拟高强钢及软钢的断裂失效,研究了高强钢及软钢的断裂失效特性以及其仿真预测方法．以宝钢高强钢HC340/590DP及软钢DC05为研究对象,首先通过不同应变率的拉伸试验和不同应力状态的断裂失效试验,来表征两种钢材的弹塑性及断裂失效行为．并从试验数据中得到LS-DYNA中的Damage Initiation and Evolution Criteria (DIEC)失效模型所需参数,建立失效模型,通过子系统试验及仿真计算对DIEC失效模型进行验证．结果表明基于准确的材料试验数据,正向建立的DIEC失效模型可以准确预测HC340/590D及DC05的断裂失效行为．本研究方法可推广到其他高强钢和软钢的断裂失效仿真预测中．     

超高强度平头圆柱形弹体对低碳合金钢板的高速撞击实验

为分析不同组分低碳合金钢板抗超高强度低碳合金钢弹体的高速撞击性能及破坏模式,以两种典型防弹特种钢SS、AS以及常见的Q235A钢为研究对象,通过静态拉伸、静态压缩及动态压缩测试,获得静态拉伸和压缩性能参数以及1 000~6 000 s-1应变率范围内的力学行为,分析了材料组分与力学性能的相关性。采用弹道枪加载撞击方法,获得了两种超高强度合金钢平头圆柱形弹体对3种钢板(14.5~15.9 mm厚)的弹道极限速度,通过分析获得了不同工况下的极限比吸收能,讨论了合金钢板在弹体高速撞击下破坏模式的差异,分析了材料力学性能与破坏模式的相关性。研究表明:3种合金钢板抗弹体撞击性能与材料屈服强度正相关,但其性能间的差异远小于屈服强度间的差异;在超高强度合金钢平头圆柱形弹体的高速撞击下,3种钢板的失效机制与其力学性能密切相关,Si和Mn含量高的AS钢呈硬脆性特征,其断裂失效主要取决于材料的剪切强度,而Si和Mn含量较低的SS钢和Q235A钢具有良好的塑性,其断裂失效主要取决于材料的压缩强度和剪切强度。     

考虑应力三轴度影响的30CrMnSiNi2A钢韧性断裂研究

30CrMnSiNi2A钢是一种在军工领域应用广泛的低合金高强度钢。针对结构完整性的评估问题,采用试验和数值计算结合的方法研究了30CrMnSiNi2A钢的韧性断裂特性。对光滑圆棒试件在不同温度下进行准静态和动态拉伸试验,并通过有限元迭代方法标定了材料的Johnson-Cook动态本构模型参数,分析了温度和应变率对30CrMnSiNi2A钢断裂行为的影响。开展了缺口圆棒拉伸、缺口平板剪切和圆柱压缩试验,计算了各试件对应的平均应力三轴度和断裂应变,给出了应力三轴度在?1/3～1.5区间内的断裂应变变化曲线,分别确定了Johnson-Cook和Bao-Wierzbicki失效模型参数。研究表明,30CrMnSiNi2A钢的断裂应变与应力状态密切相关,且在不同的应力三轴度区间内曲线单调性差异较大,Bao-Wierzbicki失效模型较好地描述了这种钢在不同应力状态下的断裂特性。     

基于夏比冲击试验的材料失效模型参数

结合夏比冲击试验和ABAQUS显式动力数值模拟,对Q370d钢进行了Johnson-Cook失效模型参数研究。首先,在不考虑材料失效的情况下,通过3种不同厚度的无缺口试件冲击实验对有限元模型参数设置和材料本构模型的准确性进行了验证,同时还讨论了试件断裂区网格的合适尺寸;在此基础上,基于正交设计,通过大量的有限元数值模拟得到失效模型参数样本,利用回归分析求得冲击功与失效模型参数的回归方程组;最后结合夏比V型缺口冲击试验,求解Q370d钢的失效模型参数,并对断裂截面的力学特性进行了分析,可为工程应用提供参考。     

加载速率对40Cr钢Ⅱ型动态断裂特性的影响

采用新型Ⅱ型动态断裂测试技术,对高强钢40Cr在高加载速率下的Ⅱ型动态断裂特性进行了测试研究。基于新设计的Ⅱ型动态断裂试样和分离式霍普金森压杆（split Hopkinson pressure bar, SHPB）技术,通过实验-数值方法确定了裂尖在加载过程中的应力强度因子曲线。采用应变片法确定了试样的起裂时间,最终得到40Cr的Ⅱ型动态断裂韧性值,并对其加载速率相关性和材料的失效机理进行了研究。结果表明,在1.08～5.53 TPa·m1/2/s的加载速率范围内,40Cr的Ⅱ型动态断裂韧性基本表现为与加载速率成正相关的变化趋势。通过对试样断口形貌的分析,确定了材料的失效模式及机理,发现随着加载速率的增加,存在拉伸型失效向绝热剪切型失效模式转变的现象。     

高强度钢船体焊接结构的安全评定

基于欧洲共同体提出的结构完整性评定方法SINTAP,对含缺陷的高强钢船体焊接接头进行安全评定.根据拉伸试验和断裂韧度试验的结果,建立了高强度钢船体焊接结构的二级失效评定曲线.评定结果表明,评定点在曲线范围内,说明该结构是安全的,取代了将焊接接头近似看作均匀材料进行评定的方法,提高了评定精度.     

双相钢板料的单向拉伸断裂失效研究(Ⅱ)——弧长法非线性有限元分析

为了获得docol800DP双相钢板料的等效塑性应变和应力三轴度在单向拉伸断裂失效过程中的变化历程,对其拉伸过程进行了弧长法非线性有限元分析。根据试验得到的材料参数建立了双相钢单向拉伸试件的有限元模型,考虑大变形引起的几何非线性和塑性强化引起的材料非线性,模拟了试件拉伸变形的全过程。计算结果表明:弧长法可较好地模拟试件变形的全程,计算得到的典型变形阶段、集中性失稳带的分布及方向与试验结果吻合很好;发生失稳变形时的应变与理论分析结果一致。最后,给出了起裂点处失效参数的变化历程,为定量化研究双相钢材料的断裂失效模型提供准确的数据支持。     

高强度铸造锌合金在干摩擦条件下摩擦磨损特性之研究

本文在干摩擦条件下对高强度铸造锌合金ZA-12和ZA-27的摩擦磨损特性进行了研究,并以锡青铜ZQSn6-6-3进行了对比试验。结果表明,这3种合金与45~#钢配磨时的摩擦系数相差不大,但前两者的磨损率都比后者的低2～3个数量级,表明高强度铸造锌合金在润滑失效时仍具有良好的拉伤抗力。     

双相钢板料的单向拉伸断裂失效研究(Ⅰ)——数字图像相关技术试验

通过数字图像相关技术试验研究了双相钢平板单向拉伸试件的拉伸变形和断裂失效过程,与理论结果对比分析了集中性失稳带的分布和方向.试验研究结果表明,试件的变形过程包括均匀变形、分散性失稳、集中性失稳和拉断4个阶段;集中性失稳的区域呈"×"形分布,与加载方向约成57°;起裂点位于局部颈缩截面的中心点处;双相钢的延伸率为18%.     

超高强度钢AF1410塑性流动特性及其本构关系

在本文中,为揭示超高强度钢AF1410的塑性流动性,并研究其塑性流动本构关系,利用CSS4410电子万能试验机和改进的Hopkinson拉压杆技术,对AF1410钢在温度从100K到600K,应变率从0.001/s到2000/s,塑性应变超过20%的塑性流动特性进行了试验研究。结果表明,拉伸加载下AF1410钢屈服强度低于压缩屈服强度,且随应变率增加,拉压屈服强度差值越来越大;该材料塑性流动应力对应变率敏感性低,而对温度较为敏感;随应变率的提高,该材料拉伸失效应变减小,但温度对失效应变无明显影响。最后基于位错的运动学关系,借助试验数据,获得了AF1410钢的塑性流动物理概念本构模型,并通过与经典J-C模型的结果对比对该物理概念本构模型进行了评估分析,表明该物理概念本构模型在较宽温度和应变率范围能较好的预测AF1410钢的塑性流动应力。     

The shear fracture of dual-phase steel

Unexpected fractures at high-curvature die radii in sheet forming operations limit the adoption of advanced high strength steels (AHSS) that otherwise offer remarkable combinations of high strength and tensile ductility. Identified as “shear fractures” or “shear failures,” these often show little sign of through-thickness localization and are not predicted by standard industrial simulations and forming limit diagrams. To understand the origins of shear failure and improve its prediction, a new displacement-controlled draw-bending test was developed, carried out, and simulated using a coupled thermo-mechanical finite element model. The model incorporates 3D solid elements and a novel constitutive law taking into account the effects of strain, strain rate, and temperature on flow stress. The simulation results were compared with companion draw-bend tests for three grades of dual-phase (DP) steel over a range of process conditions. Shear failures were accurately predicted without resorting to damage mechanics, but less satisfactorily for DP 980 steel. Deformation-induced heating has a dominant effect on the occurrence of shear failure in these alloys because of the large energy dissipated and the sensitivity of strain hardening to temperature increases of the order of 75 °C. Isothermal simulations greatly overestimated the formability and the critical bending ratio for shear failures, thus accounting for the dominant effect leading to the inability of current industrial methods to predict forming performance accurately. Use of shell elements (similar to industrial practice) contributes to the prediction error, and fracture (as opposed to strain localization) contributes for higher-strength alloys, particularly for transverse direction tests. The results illustrate the pitfall of using low-rate, isothermal, small-curvature forming limit measurements and simulations to predict the failure of high-rate, quasi-adiabatic, large-curvature industrial forming operations of AHSS.     

Numerical failure analysis of a stretch-bending test on dual-phase steel sheets using a phenomenological fracture model

Advanced High Strength Steels (AHSS) are increasingly used in automotive industry due to their superior strength and substantial weight advantage. However, their compromised ductility gives rise to numerous manufacturing issues. One of them is the so-called ‘shear fracture’ often observed on tight radii during stamping processes. Since traditional approaches, such as the Forming Limit Diagram (FLD), are unable to predict this type of fractures, great efforts have been made to develop failure criteria that could predict shear fractures. In this paper, a recently developed Modified Mohr–Coulomb (MMC) ductile fracture criterion (Bai and Wierzbicki, 2010) is adopted to analyze the failure behavior of a Dual Phase (DP) steel sheet during stretch-bending operations. The plasticity and ductile fracture of the present sheet are fully characterized by a Hill’48 orthotropic model and a MMC fracture model, respectively. Finite element models with three different element types (3D, shell and plane strain) were built for a Stretch Forming Simulator (SFS) test (Shih and Shi, 2008), numerical simulations with four different R/t values (die radius normalized by sheet thickness) were performed. It has been shown that the 3D and shell element simulations can predict failure location/mode, the upper die load–displacement responses as well as wall stress and wrap angle at the onset of fracture for all R/t values with good accuracy. Furthermore, a series of parametric studies were conducted on the 3D element model, and the effect of tension level (clamping distance), tooling friction, mesh size and fracture locus on failure modes and load–displacement responses were investigated.     

In situ 3D Synchrotron Laminography Assessment of Edge Fracture in Dual-Phase Steels: Quantitative and Numerical Analysis

The mechanical performance of automotive structures made of advanced high strength steels (AHSS) is often seen reduced by the presence of cut edges. An attempt is made to assess and quantify the initial damage state and the damage evolution during mechanical testing of a punched edge and a machined edge via a recently developed 3D imaging technique called synchrotron radiation computed laminography. This technique allows us to observe damage in regions of interest in thin sheet-like objects at micrometer resolution. In terms of new experimental mechanics, steel sheets having sizes and mechanical boundary conditions of engineering relevance can be tested for the first time with in situ 3D damage observation and quantification. It is found for the investigated DP600 steel that the fracture zone of the punched edge is rough and that needle-shape voids at the surface and in the bulk follow ferrite-martensite flow lines. During mechanical in situ testing the needle voids grow from the fracture zone surface and coalesce with the sheared zone. In contrast, during in situ mechanical testing of a machined edge the damage starts away from the edge (～800μm) where substantial necking has occurred. Three-dimensional image analysis was performed to quantify the initial damage and its evolution. These data can be used as input and validation data for micromechanical damage models. To interpret the experimental findings in terms of mechanical fields, combined surface digital image correlation and 3D finite element analysis were carried out using an elasto-plastic constitutive law of the investigated DP steel. The stress triaxiality and the accumulated plastic strain were calculated in order to understand the influence of the edge profile and the hardening of the cutting-affected zone on the mechanical fields.     

Prediction of plane strain fracture of AHSS sheets with post-initiation softening

In this investigation, the three-parameter Modified Mohr–Coulomb (MMC) fracture model and the determination of the material parameters are briefly described. The formulation of the post-initiation behavior is proposed by defining both the explicit softening law and the incremental damage evolution law. As opposed to the existing attempts to simulate slant fracture with material weakening before crack formation, softening is assumed to occur only in the post-initiation range. The justification of this assumption can be provided by the interrupted fracture tests, for example, Spencer et al. (2002).Element deletion with a gradual loss of strength is used to simulate crack propagation after fracture initiation. The main emphasis of the paper is the numerical prediction of slant fracture which is almost always observed in thin sheets. For that purpose, VUMAT subroutines of ABAQUS are coded with post-initiation behavior for both shell elements and plane strain elements. Fracture of flat-grooved tensile specimens cut from advanced high strength steel (AHSS) sheets are simulated by 2D plane strain element and shell element models.     

Evaluation of the VDA 238–100 Tight Radius Bend Test for Plane Strain Fracture Characterization of Automotive Sheet Metals

Accurate characterization of the fracture limit in plane strain tension of automotive sheet metals is critical for the design and crash performance of structural components. Plane strain bending using the VDA 238–100 V-bend test has potential for proportional fracture characterization by avoiding a tensile instability. The VDA 238–100 V-bend test was evaluated using DIC strain measurement to characterize the plane strain fracture limit under proportional plane stress loading and to evaluate the effect of the VDA pre-straining methodology for ductile alloys upon the material response. The load-based failure criterion of the V-bend test was evaluated with DIC to monitor the development of surface cracking. The influence of the non-linear strain path imposed by the pre-straining procedure for ductile materials was then evaluated for three automotive alloys: an advanced high strength dual phase steel, DP1180, a rare-earth magnesium, ZEK100, and an AA5182 aluminum. A fracture criterion based on the load threshold was reasonable for the three alloys considered. Pre-straining in uniaxial tension prior to plane strain bending affected each alloy differently. The DP1180 was not affected by the non-linear strain path whereas the cumulative equivalent strain for the AA5182 and ZEK100 increased by strains of 0.07 and 0.05 strain, respectively. The non-linear strain path within the VDA pre-straining methodology creates ambiguity in comparing the fracture limits of different materials. The plane strain fracture limit for proportional loading can be readily obtained in the V-bend test with DIC strain measurement.

     

Application of Laser Deposition to Mechanical Characterization of Advanced High Strength Steels Subject to Non-Proportional Loading

Background

Characterization of hardening and fracture limits of advanced high strength steels (AHSSs) undergoing strain path changes (SPCs) are particularly challenging for plane strain condition, which commonly occurs in sheet metal forming. There is a need for a simple, engineering-friendly method to characterize materials subjected to complex loading paths that mimic stress conditions in actual forming processes.

Objective

Experimental additive manufacturing techniques have been applied to reinforce AHSS specimens subjected to SPCs in order to broaden capabilities for characterizing hardening behavior and fracture limits.

Methods

Hardening curves subject to SPCs (e.g. uniaxial tension or equi-biaxial tension followed by plane strain) have been obtained with a programmable biaxial tensile testing system using cruciform-shaped specimens with load-bearing arms reinforced by laser deposition. A notched specimen selectively reinforced by laser deposition was newly designed to characterize fracture limits subjected to SPCs ending with plane strain condition.

Results

Complex loading histories were successfully enabled by applying laser deposition technology. Results show that both hardening behavior and fracture limits of a TRIP-assisted steel and a dual-phase steel are dependent on loading history.

Conclusions

It appears that the laser deposition technique can be used for material characterization under specific SPCs. Hardening behavior of AHSSs under SPCs ending with plane strain is quite different from traditional uniaxial tension-uniaxial compression tests. For materials sensitive to SPCs, multi-step forming can be a great option to reach the targeted forming shape.

     

各向异性编织CMC弯曲断裂失效模型

通过对缺口弯曲断裂试验的研究发现，编织CMC存在两种断裂失效模式：界面主导的和纤维束主导的失效模式．针对这两种模式建立了界面失效模型和纤维束断裂失效模型．界面失效模型用半经验方法处理弱界面和大编织角度的断裂强度问题；纤维束断裂失效模型采用解析方法处理较强界面和小角度的断裂强度问题，为含有缺口试件的弯曲强度预报打下了初步的理论基础．     

约束修正失效评定曲线及内压管道失效分析

用A2参数描述裂纹尖端约束效应,考虑裂纹尖端约束水平对断裂阻力的影响,对R6失效评定曲线进行修正。以X80钢为例,根据不同约束水平试件测试得到的JR–△a曲线,给出了与裂纹尖端约束相关的失效评定曲线。在使用有限元对带裂纹内压管道进行弹塑性分析的基础上,利用失效评定曲线对失效载荷进行预测;与试验结果比较表明:采用约束修正失效评定曲线,在对存在缺陷的构件进行安全性评定、寿命评估、失效概率计算时,考虑约束效应对断裂韧度的影响可以更充分地发挥构件的强度潜力。