Strain localization analysis using a large deformation anisotropic elastic–plastic model coupled with damage

Sheet metal forming processes generally involve large deformations together with complex loading sequences. In order to improve numerical simulation predictions of sheet part forming, physically-based constitutive models are often required. The main objective of this paper is to analyze the strain localization phenomenon during the plastic deformation of sheet metals in the context of such advanced constitutive models. Most often, an accurate prediction of localization requires damage to be considered in the finite element simulation. For this purpose, an advanced, anisotropic elastic–plastic model, formulated within the large strain framework and taking strain-path changes into account, has been coupled with an isotropic damage model. This coupling is carried out within the framework of continuum damage mechanics. In order to detect the strain localization during sheet metal forming, Rice’s localization criterion has been considered, thus predicting the limit strains at the occurrence of shear bands as well as their orientation. The coupled elastic–plastic-damage model has been implemented in Abaqus/implicit. The application of the model to the prediction of Forming Limit Diagrams (FLDs) provided results that are consistent with the literature and emphasized the impact of the hardening model on the strain-path dependency of the FLD. The fully three-dimensional formulation adopted in the numerical development allowed for some new results – e.g. the out-of-plane orientation of the normal to the localization band, as well as more realistic values for its in-plane orientation.     

On the modelling of anisotropic elastic and inelastic material behaviour at large deformation

The purpose of this work is the formulation and discussion of an approach to the modelling of anisotropic elastic and inelastic material behaviour at large deformation. This is done in the framework of a thermodynamic, internal-variable-based formulation for such a behaviour. In particular, the formulation pursued here is based on a model for plastic or inelastic deformation as a transformation of local reference configuration for each material element. This represents a slight generalization of its modelling as an elastic material isomorphism pursued in earlier work, allowing one in particular to incorporate the effects of isotropic continuum damage directly into the formulation. As for the remaining deformation- and stress-like internal variables of the formulation, these are modelled in a fashion formally analogous to so-called structure tensors. On this basis, it is shown in particular that, while neither the Mandel nor back stress is generally so, the stress measure thermodynamically conjugate to the plastic “velocity gradient”, containing the difference of these two stress measures, is always symmetric with respect to the Euclidean metric, i.e., even in the case of classical or induced anisotropic elastic or inelastic material behaviour. Further, in the context of the assumption that the intermediate configuration is materially uniform, it is shown that the stress measure thermodynamically conjugate to the plastic velocity gradient is directly related to the Eshelby stress. Finally, the approach is applied to the formulation of metal plasticity with isotropic kinematic hardening.     

Elastoplastic deformations of rotating parabolic solid disks using Tresca''s yield criterion

Analytical solutions for the stress distribution in rotating parabolic solid disks are obtained. The analysis is based on Tresca's yield criterion, its associated flow rule and linear strain hardening. It is shown that, the deformation behavior of the convex parabolic disk is similar to that of the uniform thickness disk, but in the case of concave parabolic solid disk, it is different. In the latter, the plastic core consists of three different plastic regions with different mathematical forms of the yield criteria. Accordingly, three different stages of elastic–plastic deformation occur. All these stages of elastic–plastic deformation are studied in detail. It is also shown mathematically that in the limiting case the parabolic disk solution reduces to the solution of rotating uniform thickness solid disk.     

On non-associative anisotropic finite plasticity fully coupled with isotropic ductile damage for metal forming

In this work, non-associative finite strain anisotropic elastoplasticity fully coupled with ductile damage is considered using a thermodynamically consistent framework. First, the kinematics of large strain based on multiplicative decomposition of the total transformation gradient using the rotating frame formulation, is recalled and different objective derivatives defined. By using different anisotropic equivalent stresses (quadratic and non-quadratic) in yield function and in plastic potential, the evolution equations for all the dissipative phenomena are deduced from the generalized normality rule applied to the plastic potential while the consistency condition is still applied to the yield function. The effect of the objective derivatives and the equivalent stresses (quadratic or non-quadratic) on the plastic flow anisotropy and the hardening evolution with damage is considered. Numerical aspects mainly related to the time integration of the fully coupled constitutive equations are discussed. Applications are made to the AISI 304 sheet metal by considering different loading paths as tensile, shear, plane tensile and bulge tests. For each loading path the effect of the rotating frame, the equivalent stress (quadratic or non-quadratic) and the normality rule (with respect to yield function or to the plastic potential) are discussed on the light of some available experimental results.     

A model for the through-thickness elastic–plastic behaviour of paper

An elastic–plastic material model for the out-of-plane mechanical behaviour of paper is presented. This model enables simulation the elastic–plastic behaviour under high compressive loads in the through-thickness direction (ZD). Paper does not exhibit a sharp transition from elastic to elastic–plastic behaviour. This makes it advantageous to define critical stress states based on failure stresses rather than yield stresses. Moreover, the failure stress in out-of-plane shear is strongly affected by previous plastic through-thickness compression. To cover these two features, a model based on the idea of a bounding surface that grows in size with plastic compression is proposed. Here, both the bounding and the yield surfaces are suggested as parabolas in stress space. While the bounding surface is open for compressive loads, the yield surface is bordered by the maximum applied through-thickness compression.     

Numerical analysis of elastic–plastic rotating disks with arbitrary variable thickness and density

A unified numerical method is developed in this article for the analysis of deformations and stresses in elastic–plastic rotating disks with arbitrary cross-sections of continuously variable thickness and arbitrarily variable density made of nonlinear strain-hardening materials. The method is based on a polynomial stress–plastic strain relation, deformation theory in plasticity and Von Mises’ yield condition. The governing equation is derived from the basic equations of the rotating disks and solved using the Runge–Kutta algorithm. The proposed method is applied to calculate the deformations and stresses in various rotating disks. These disks include solid disks with constant thickness and constant density, annular disks with constant thickness and constant density, nonlinearly variable thickness and nonlinearly variable density, linearly tapered thickness and linearly variable density, and a combined section of continuously variable thickness and constant density. The computed results are compared to those obtained from the finite element method and the existing approaches. A very good agreement is found between this research and the finite element analysis. Due to the simplicity, effectiveness and efficiency of the proposed method, it is especially suitable for the analysis of various rotating disks.     

Shakedown in elastic contact problems with Coulomb friction

Elastic systems with frictional interfaces subjected to periodic loading are sometimes predicted to ‘shake down’ in the sense that frictional slip ceases after the first few loading cycles. The similarities in behaviour between such systems and monolithic bodies with elastic–plastic constitutive behaviour have prompted various authors to speculate that Melan’s theorem might apply to them – i.e., that the existence of a state of residual stress sufficient to prevent further slip is a sufficient condition for the system to shake down.In this paper, we prove this result for ‘complete’ contact problems in the discrete formulation (i) for systems with no coupling between relative tangential displacements at the interface and the corresponding normal contact tractions and (ii) for certain two-dimensional problems in which the friction coefficient at each node is less than a certain critical value. We also present counter-examples for all systems that do not fall into these categories, thus giving a definitive statement of the conditions under which Melan’s theorem can be used to predict whether such a system will shake down.     

Transient analysis of ionic replacements in elastic–plastic expansive clays

Chemically active saturated clays are considered in a two-phase framework. The solid phase contains clay particles, absorbed water and dissolved ions, Na⁺, K⁺ and Cl⁻. The fluid phase, or pore water, contains free water and the same ionic species. Water and ions can transfer between the two phases. In addition, they diffuse through the porous medium. A global understanding of all phenomena, mass transfer, diffusion/advection and deformation is provided. The coupled constitutive equations associated to these phenomena are developed. Emphasis is laid on the electro-chemo-mechanical constitutive equations in an elastic–plastic setting.A finite element formulation embodying all the above aspects is proposed and simulations of oedometer tests are presented and commented. Of particular interest are the consolidation and swelling that occur during salinization and desalinization of an external reservoir in contact with the specimen, and the more subtle, but important effects of replacing an NaCl pore solution by a KCl pore solution, and conversely.     

The formulation of constitutive equations for fibre-reinforced composites in plane problems: Part II

Summary From the continuum mechanics points of view, most of commercial fibre-reinforced composites (FRCs) can be considered to be anisotropic materials with one of the five material symmetries: transverse isotropy, orthotropy, tetratropy, hexatropy and octotropy, as illustrated in the preceding paper (Part I) [1]. No properly general formulation of constitutive equations for tetratropic, hexatropic and octoctropic types of FRC has been found in the literature. In this paper, the restriction to the admissible deformation of a FRC imposed by the failure strains of the fibres is investigated. The complete and irreducible two-dimensional tensor function representations regarding tetratropy, hexatropy and octotropy derived in Part I are applied to formulate constitutive equations for FRCs in plane problems of elasticity, yielding and failure in the present work, and of heat conduction, continuum damage and asymmetric elasticity in a continued work (Part III, forthcoming).The supports from the Alexander von Humboldt Foundation, Germany and the Research Foundation of Tsinghua University, P. R. China are acknowledged by the first author.     

Numerical simulation of plastic-flow localization for simple shear

An algorithm was developed to numerically simulate plastic-flow localization for simple shear of a thermally plastic and viscoplastic material. The algorithm is based on solving the partial differential equations describing continuum flow. The closing equation is the constitutive relation known in the literature as the power law linking the plastic-strain rate to the flow stress, temperature, and accumulated plastic strain. Calculated relations for the time evolution of the shear-band width and the temperature and plastic strains localized in it agree satisfactorily with experimental relations. Good agreement with experimental results is also obtained for the sample temperature distribution at the developed stage of the localization process.Translated from Prikladnaya Mekhanika i Tekhnicheskaya Fizika, Vol. 46, No. 1, pp. 173–180, January–February, 2005     

An application of Curie’s principle to elastoplastic dynamics

This paper deals with the stability and the dynamics of a harmonically excited elastic–perfectly plastic unsymmetrical oscillator. Stability of the periodic orbits is analytically investigated with a perturbation approach. The occurrence of ratcheting effect is discussed for this system, and is related to the loss of symmetry of the periodic orbit in the phase space. Curie’s principle of symmetry is numerically verified for the symmetrical system with positive damping. Therefore, the observation of ratcheting phenomenon is necessarily associated to a breaking of symmetry in the constitutive behaviour, or in the forcing term. However, the generalized version of Curie’s principle has to be considered when a negative damping is introduced.     

Propagation of Normal Axisymmetric Waves in Compliant Elastic Cylinders Filled with and Immersed in a Fluid

The paper studies the relationship between the physical characteristics of a cylinder and the properties of normal axisymmetric waves in elastic–liquid waveguides. The cylinder is made of a compliant material in which the velocity of shear waves is less than the sonic velocity in a perfect compressible liquid. The complete system of dynamic elasticity equations and the wave equation are used to describe the wave fields in the elastic cylinder and fluid, respectively. This approach allows obtaining the dispersion characteristics of coupled normal waves in compound waveguides over wide ranges of frequencies and wavelengths. The curves of real, imaginary, and complex wave numbers versus frequency are plotted for specific pairs of waveguide materials. Computations are carried out for a thick-walled cylinder filled with a fluid and immersed in either vacuum or a fluid. It is found out that compliant and rigid materials of the cylinder affect differently the wave interaction process in elastic–liquid waveguides     

Unit cell debonding analyses for arbitrary orientation of plastic anisotropy

Debonding of rigid inclusions embedded in the elastic–plastic aluminum alloy Al 2090-T3 is analyzed numerically using a unit cell model taking full account of finite strains. The cell is subjected to overall biaxial plane strain tension and periodical boundary conditions are applied to represent arbitrary orientations of plastic anisotropy. Plastic anisotropy is considered using two phenomenological anisotropic yield criteria, namely Hill [Proceedings of the Royal Society of London A 193 (1948) 281] and Barlat et al. [International Journal of Plasticity 7 (1991) 693]. For this material plastic anisotropy delays debonding compared to plastic isotropy except for the case of Hill’s yield function when the tensile directions coincided with the principal axes of anisotropy. For some inclinations of the principal axes of anisotropy relative to the tensile directions, the stress strain responses are identical but the deformation modes are mirror images of each other.     

A theoretical and computational framework for anisotropic continuum damage mechanics at large strains

The main objective of this work is the formulation and algorithmic treatment of anisotropic continuum damage mechanics at large strains. Based on the concept of a fictitious, isotropic, undamaged configuration an additional linear tangent map is introduced which allows the interpretation as a damage deformation gradient. Then, the corresponding Finger tensor – denoted as damage metric – constructs a second order, internal variable. Due to the principle of strain energy equivalence with respect to the fictitious, effective space and the standard reference configuration, the free energy function can be computed via push-forward operations within the nominal setting. Referring to the framework of standard dissipative materials, associated evolution equations are constructed which substantially affect the anisotropic nature of the damage formulation. The numerical integration of these ordinary differential equations is highlighted whereby two different schemes and higher order methods are taken into account. Finally, some numerical examples demonstrate the applicability of the proposed framework.     

An anisotropic elastoplastic constitutive formulation generalised for orthotropic materials

This paper presents a finite strain constitutive model to predict a complex elastoplastic deformation behaviour that involves very high pressures and shockwaves in orthotropic materials using an anisotropic Hill’s yield criterion by means of the evolving structural tensors. The yield surface of this hyperelastic–plastic constitutive model is aligned uniquely within the principal stress space due to the combination of Mandel stress tensor and a new generalised orthotropic pressure. The formulation is developed in the isoclinic configuration and allows for a unique treatment for elastic and plastic orthotropy. An isotropic hardening is adopted to define the evolution of plastic orthotropy. The important feature of the proposed hyperelastic–plastic constitutive model is the introduction of anisotropic effect in the Mie–Gruneisen equation of state (EOS). The formulation is further combined with Grady spall failure model to predict spall failure in the materials. The proposed constitutive model is implemented as a new material model in the Lawrence Livermore National Laboratory (LLNL)-DYNA3D code of UTHM’s version, named Material Type 92 (Mat92). The combination of the proposed stress tensor decomposition and the Mie–Gruneisen EOS requires some modifications in the code to reflect the formulation of the generalised orthotropic pressure. The validation approach is also presented in this paper for guidance purpose. The \({\varvec{\psi }}\) tensor used to define the alignment of the adopted yield surface is first validated. This is continued with an internal validation related to elastic isotropic, elastic orthotropic and elastic–plastic orthotropic of the proposed formulation before a comparison against range of plate impact test data at 234, 450 and \({\mathrm {895\,ms}}^{\mathrm {-1}}\) impact velocities is performed. A good agreement is obtained in each test.     

Thermodynamic laws and consistent Eulerian formulation of finite elastoplasticity with thermal effects

Recently it has been demonstrated that, on the basis of the separation D=D^e+D^p arising from the split of the stress power and two consistency criteria for objective Eulerian rate formulations, it is possible to establish a consistent Eulerian rate formulation of finite elastoplasticity in terms of the Kirchhoff stress and the stretching, without involving additional deformation-like variables labelled “elastic” or “plastic”. It has further been demonstrated that this consistent formulation leads to a simple essential structure implied by the work postulate, namely, both the normality rule for plastic flow D^p and the convexity of the yield surface in Kirchhoff stress space. Here, we attempt to place such an Eulerian formulation on the thermodynamic grounds by extending it to a general case with thermal effects, where the consistency requirements are treated in a twofold sense. First, we propose a general constitutive formulation based on the foregoing separation as well as the two consistency criteria. This is accomplished by employing the corotational logarithmic rate and by incorporating an exactly integrable Eulerian rate equation for D^e for thermo-elastic behaviour. Then, we study the consistency of the formulation with thermodynamic laws. Towards this goal, simple forms of restrictions are derived, and consequences are discussed. It is shown that the proposed Eulerian formulation is free in the sense of thermodynamic consistency. Namely, a Helmholtz free energy function in explicit form may be found such that the restrictions from the thermodynamic laws can be fulfilled with positive internal dissipation for arbitrary forms of constitutive functions included in the constitutive formulation. In particular, that is the case for the foregoing essential constitutive structure in the purely mechanical case. These results eventually lead to a complete, explicit constitutive theory for coupled fields of deformation, stress and temperature in thermo-elastoplastic solids at finite deformations.