A thermo-mechanical cohesive zone formulation for ductile fracture

The paper addresses the possibility to project both mechanical and thermal phenomena pertinent to the fracture process zone into a cohesive zone. A wider interpretation of the notion cohesive zone is thereby suggested to comprise not only stress degradation due to micro-cracking but also heat generation and energy transport. According to our experience, this widening of the cohesive zone concept allows for a more efficient finite element simulation of ductile fracture. The key feature of the formulation concerns the thermo-mechanical cohesive zone model, evolving within the thermo-hyperelastoplastic continuum, allowing for the concurrent modelling of both heat generation, due to the fracture process, and heat transfer across the fracture process zone. This is accomplished via thermodynamic arguments to obtain the coupled governing equation of motion, energy equation, and constitutive equations. The deformation map is thereby defined in terms of independent continuous and discontinuous portions of the displacement field. In addition, as an extension of the displacement kinematics, to represent the temperature field associated with the discontinuous heat flux across the fracture interface, a matching discontinuous temperature field involving the interface (or band) temperature is proposed. In the first numerical example, concerning dynamic quasi-brittle crack propagation in a thermo-hyperelastoplastic material, we capture the initial increase in temperature close to the crack surface due to the energy dissipating fracture process. In the second example, a novel application of ductile fracture simulation to the process of high velocity (adiabatic) cutting is considered, where some general trends are observed when varying the cutting velocity.     

A simple cohesive zone model that generates a mode-mixity dependent toughness

A simple, mode-mixity dependent toughness cohesive zone model (MDG_c CZM) is described. This phenomenological cohesive zone model has two elements. Mode I energy dissipation is defined by a traction–separation relationship that depends only on normal separation. Mode II (III) dissipation is generated by shear yielding and slip in the cohesive surface elements that lie in front of the region where mode I separation (softening) occurs. The nature of predictions made by analyses that use the MDG_c CZM is illustrated by considering the classic problem of an elastic layer loaded by rigid grips. This geometry, which models a thin adhesive bond with a long interfacial edge crack, is similar to that which has been used to measure the dependence of interfacial toughness on crack-tip mode-mixity. The calculated effective toughness vs. applied mode-mixity relationships all display a strong dependence on applied mode-mixity with the effective toughness increasing rapidly with the magnitude of the mode-mixity. The calculated relationships also show a pronounced asymmetry with respect to the applied mode-mixity. This dependence is similar to that observed experimentally, and calculated results for a glass/epoxy interface are in good agreement with published data that was generated using a test specimen of the same type as analyzed here.     

A refined cohesive zone model that accounts for inertia of cohesive zone of a moving crack

Existing cohesive zone models assume that actual fracture zone of non-zero mass can be modeled by a line segment (cohesive zone) with no mass and inertia. In the present work, a simplified mass-spring model is presented to study inertia effect of cohesive zone on a mode-I steady-state moving crack. It is showed that fracture energy predicted by the present model increases dramatically when a finite limiting crack speed is approached. Reasonable agreement with known experiments indicates that the present model has the potential to catch the inertia effect of cohesive zone which has been ignored in existing cohesive zone models and better simulate dynamic fracture at high crack speed.     

Homogenization scheme for brittle intergranular decohesion in polycrystalline aggregates

The overall fracture behaviour of polycrystalline aggregates is strongly conditioned by intergranular failure, as is the case in copper alloys subjected to dynamic embrittlement. The self-consistent scheme is extended to account for grain boundary decohesion using a nonlinear cohesive law. The effective tensile response up to failure is computed for a Cu–Ni–Si alloy based on the homogenization method. In particular, the proposed approach allows for identification of the grain boundary critical energy release rate from the macroscopic tensile curve.     

Theoretical development and experimental validation of a thermally dissipative cohesive zone model for dynamic fracture of amorphous polymers

A thermally dissipative cohesive zone model is developed for predicting the temperature increase at the tip of a crack propagating dynamically in a nominally brittle material exhibiting a cohesive-type failure such as crazing. The model assumes that fracture energy supplied to the crack tip region that is in excess of that needed for the creation of new free surfaces during crack advance is converted to heat within the cohesive zone. Bulk dissipation mechanisms, such as plasticity, are not accounted for. Several cohesive traction laws are examined, and the model is then used to make predictions of crack tip heating at various crack propagation speeds in the nominally brittle amorphous polymer PMMA, observed to fail by a crazing-type mechanism. The heating predictions are compared to experimental data where the temperature field surrounding a high speed crack in PMMA was measured. Measurements are made in real time using a multi-point high speed HgCdTe infrared radiation detector array. At the same time as temperature, simultaneous measurement of fracture energy is made by a strain gauge technique, and crack tip speed is monitored through a resistance ladder method. Material strength can be estimated through uniaxial tension tests, thus minimizing the need for parameter fitting in the stress-opening traction law. Excellent agreement between experiments and theory is found for two of the cohesive traction law temperature predictions, but only for the case where a single craze is active during the dynamic fracture of PMMA, i.e. crack tip speed up to approximately 0.2c_R. For higher speed fracture where subsurface damage becomes prominent, the line dissipation model of a cohesive zone is inadequate, and a distributed damage model is needed.     

A statistical, physical-based, micro-mechanical model of hydrogen-induced intergranular fracture in steel

Intergranular cracking associated with hydrogen embrittlement represents a particularly severe degradation mechanism in metallic structures which can lead to sudden and unexpected catastrophic fractures. As a basis for a strategy for the prognosis of such failures, here we present a comprehensive physical-based statistical micro-mechanical model of such embrittlement which we use to quantitatively predict the degradation in fracture strength of a high-strength steel with increasing hydrogen concentration, with the predictions verified by experiment. The mechanistic role of dissolved hydrogen is identified by the transition to a locally stress-controlled fracture, which is modeled as being initiated by a dislocation pile-up against a grain-boundary carbide which in turn leads to interface decohesion and intergranular fracture. Akin to cleavage fracture in steel, the “strength” of these carbides is modeled using weakest-link statistics. We associate the dominant role of hydrogen with trapping at dislocations; this trapped hydrogen reduces the stress that impedes dislocation motion and also lowers the reversible work of decohesion at the tip of dislocation pile-up at the carbide/matrix interface. Mechanistically, the model advocates the synergistic action of both the hydrogen-enhanced local plasticity and decohesion mechanisms in dictating failure.     

Coupled mixed-mode cohesive zone modeling of interfacial debonding in simply supported plated beams

The development of predictive models for plate end debonding failures in beams strengthened with thin soffit plates is a topic of great practical relevance. After the early stress-based formulations, fracture mechanics approaches have become increasingly established. More recently, the cohesive zone (CZ) model has been successfully adopted as a bridge between the stress- and fracture mechanics-based treatments. However, the few studies of this nature propose complex formulations which can only be implemented numerically. To date, the only available analytical solution based on CZ modeling for the prediction of interfacial stresses/debonding in plated beams is limited to the determination of interfacial shear stresses and thus neglects the mixed-mode effects generated by the presence of interfacial normal stresses at the plate end. This paper presents a new analytical formulation based on the CZ modeling approach for the prediction of plate end debonding in plated beams. A key enhancement with respect to the previous solution is the use of a coupled mixed-mode CZ model, which enables a full account of mixed-mode effects at the plate end. The model describes the evolution of the interface after the end of the elastic regime, and predicts the value of the load at incipient debonding. The achievement of a closed-form solution for this quite complex case entails the introduction of a crucial simplifying assumption, as well as the ad hoc modeling of an effective cohesive interfacial response. The paper presents the analytical theory and compares its predictions with numerical and experimental results.     

Steady growth of a crack with a rate and temperature sensitive cohesive zone

The steady-state dynamic propagation of a crack in a heat conducting elastic body is numerically simulated. Specifically, a mode III semi-infinite crack with a nonlinear temperature dependent cohesive zone is assumed to be moving in an unbounded homogeneous linear thermoelastic continuum. The numerical results are obtained via a semi-analytical technique based on complex variables and integral transforms. The relation between the thermo-mechanical properties of the failure zone and the resulting crack growth regime are investigated. The results show that temperature dependent solutions are substantially different from purely mechanical ones in that their existence and stability strongly depends on the cohesive zone thermal properties.     

Cohesive zone laws for void growth — II. Numerical field projection of elasto-plastic fracture processes with vapor pressure

Modeling ductile fracture processes using Gurson-type cell elements has achieved considerable success in recent years. However, incorporating the full mechanisms of void growth and coalescence in cohesive zone laws for ductile fracture still remains an open challenge. In this work, a planar field projection method, combined with equilibrium field regularization, is used to extract crack-tip cohesive zone laws of void growth in an elastic-plastic solid. To this end, a single row of void-containing cell elements is deployed directly ahead of a crack in an elastic-plastic medium subjected to a remote K-field loading; the macroscopic behavior of each cell element is governed by the Gurson porous material relation, extended to incorporate vapor pressure effects. A thin elastic strip surrounding this fracture process zone is introduced, from which the cohesive zone variables can be extracted via the planar field projection method. We show that the material's initial porosity induces a highly convex traction-separation relationship — the cohesive traction reaches the peak almost instantaneously and decreases gradually with void growth, before succumbing to rapid softening during coalescence. The profile of this numerically extracted cohesive zone law is consistent with experimentally determined cohesive zone law in Part I for multiple micro-crazing in HIPS. In the presence of vapor pressure, both the cohesive traction and energy are dramatically lowered; the shape of the cohesive zone law, however, remains highly convex, which suggests that diffusive damage is still the governing failure mechanism.     

Inverse parameter identification of cohesive zone model for simulating mixed-mode crack propagation

Inverse analysis is widely applied to the identification of material properties or model parameters. In order to improve the computational efficiency of the inverse method based on the genetic algorithm, an interpolation scheme upon the response surface constructed by the finite element simulation has been adopted in this paper. Meanwhile, a gradual homogenization treatment scheme has also been presented to improve the convergence of the inverse method based on the Kalman filter algorithm. Both methods are proven effective in dealing with the single-objective inverse problem. However, literature studies show that the adoption of multiple types of experimental information is useful to improve the accuracy of inverse analysis. In this case, it turns into a multiple-objective inverse problem. Our practice proved that the above-mentioned two methods might not yield a proper result if the sensitivity issue of different types of information is not considered. Therefore, another multi-objective inverse method, in combination of the above two optimization algorithms and a weight-estimating scheme that can consider such sensitivity, has been further presented. Finally, by using a mixed-mode crack propagation simulation and two types of experimental information (loading-displacement response curve and crack path profile), the parameters of the cohesive zone model were inversely identified and its simulation results are in good agreement with the experiment.     

CRACK PROPAGATION IN POLYCRYSTALLINE ELASTIC-VISCOPLASTIC MATERIALS USING COHESIVE ZONE MODELS

Cohesive zone model was used to simulate two-dimensional plane strain crack propagation at the grain level model including grain boundary zones. Simulated results show that the original crack-tip may not be separated firstly in an elastic-viscoplastic polycrystals. The grain interior's material properties (e.g. strain rate sensitivity) characterize the competitions between plastic and cohesive energy dissipation mechanisms. The higher the strain rate sensitivity is, the larger amount of the external work is transformed into plastic dissipation energy than into cohesive energy, which delays the cohesive zone rupturing. With the strain rate sensitivity decreased, the material property tends to approach the elastic-plastic responses. In this case, the plastic dissipation energy decreases and the cohesive dissipation energy increases which accelerates the cohesive zones debonding. Increasing the cohesive strength or the critical separation displacement will reduce the stress triaxiality at grain interiors and grain boundaries. Enhancing the cohesive zones ductility can improve the matrix materials resistance to void damage.     

Prediction of fracture in the vicinity of friction surfaces in metal forming processes

It is shown that the use of a fracture criterion containing a characteristic length of the flow region makes it possible to further develop the theory of fracture in the vicinity of the maximum friction surfaces in metal-forming processes, with allowance for an infinite equivalent strain rate arising near such surfaces. A model of perfectly plastic rigid solids is considered in formulating the criterion. It is noted that the approach can be extended to more complicated models of plastic solids. __________ Translated from Prikladnaya Mekhanika i Tekhnicheskaya Fizika, Vol. 47, No. 5, pp. 169–174, September–October, 2006.     

3-D numerical simulation of fracture processes in heterogeneous brittle materials

By using the lattice model combined with finite element methods and statistical techniques, a numerical approach is developed to establish mechanical models of three-dimensional heterogeneous brittle materials. A special numerical code is introduced, in which a lattice model and statistical approaches are used to simulate the initial heterogeneity of material properties. The size of displacement-load step is adaptively determined so that only few elements would fail in each load step. When the tensile principal strain in an element exceeds the ultimate strain of this element, the element is considered broken and its Young's modulus is set to be very low. Some important behaviors of heterogeneous brittle materials are indicated using this code. Load-displacement curves and figures of three-dimensional fracture patterns are also numerically obtained, which are similar to those observed in laboratory tests.     

Cohesive fracture simulation and failure modes of FRP–concrete bonded interfaces

A work-of-fracture method using three-point bend beam (3PBB) specimen, commonly employed to determine the fracture energy of concrete, is adapted to evaluate the mode-I cohesive fracture of fiber reinforced plastic (FRP) composite–concrete adhesively bonded interfaces. In this study, a bilinear damage cohesive zone model (CZM) is used to simulate cohesive fracture of FRP–concrete bonded interfaces. The interface cohesive process damage model is proposed to simulate the adhesive–concrete interface debonding; while a tensile plastic damage model is used to account for the cohesive cracking of concrete near the bond line. The influences of the important interface parameters, such as the interface cohesive strength, concrete tensile strength, critical interface energy, and concrete fracture energy, on the interface failure modes and load-carrying capacity are discussed in detail through a numerical finite element parametric study. The results of numerical simulations indicate that there is a transition of the failure modes controlling the interface fracture process. Three failure modes in the mode-I fracture of FRP–concrete interface bond are identified: (1) complete adhesive–concrete interface debonding (a weak bond), (2) complete concrete cohesive cracking near the bond line (a strong bond), and (3) a combined failure of interface debonding and concrete cohesive cracking. With the change of interface parameters, the transition of failure modes from interface debonding to concrete cohesive cracking is captured, and such a transition cannot be revealed by using a conventional fracture mechanics-based approach, in which only an energy criterion for fracture is employed. The proposed cohesive damage models for the interface and concrete combined with the numerical finite element simulation can be used to analyze the interface fracture process, predict the load-carrying capacity and ductility, and optimize the interface design, and they can further shed new light on the interface failure modes and transition mechanism which emulate the practical application.     

基于扩展有限元的地质聚合物混凝土断裂过程研究

扩展有限元法是基于常规有限元框架分析裂纹等不连续力学问题的一种有效数值方法,在常规的有限元位移表达式中,增加了能够反映位移不连续性的跳跃函数和渐进缝尖位移场函数来对不连续结构附近的节点自由度进行局部加强。本文介绍了扩展有限元法及粘聚力模型的基本原理,给出了基于扩展有限元法的地质聚合物混凝土断裂过程分析方法。分别采用四种不同的软化曲线对I型缺口地质聚合物混凝土梁从裂纹萌生、扩展直至断裂破坏的全过程进行了模拟,并基于双K断裂准则分析了其断裂韧性。结果表明,Petersson模型与试验结果吻合较好,最后基于模拟结果进一步揭示了断裂过程区的演化过程。     

压电复合材料粘接界面断裂有限元模拟

根据数字化FRMM(Fix-Ratio Mix-Mode)断裂试验,得到了压电复合材料试件的断裂韧性和位移及应变场。本文在试验的基础上,通过非线性有限元软件ABAQUS及用户子程序UMAT进行了模拟分析,采用基于损伤力学的粘聚区模型(CZM)对压电复合材料界面的起裂和脱胶扩展进行了分析,并与VCCT方法进行了比较。计算得到的荷载位移曲线更接近于试验结果,但在裂纹扩展路径上的吻合需要对粘聚区法则进一步修正。通过进一步对CZM参数进行分析,表明界面粘结强度和界面刚度对计算结果的影响很大。研究结果表明,粘聚区模型可以很好地表征压电复合材料弱粘接界面脱胶断裂问题。     

Study into the kinetics of a crack with a nonsmall fracture process zone in an aging viscoelastic plate

The subcritical growth of a mode I crack with nonsmall end zones in an aging viscoelastic plate under tensile loads applied at infinity is studied assuming that the fracture process zone is of constant length. The equations of incubation, transition, and major crack growth stages are obtained on the basis of the Volterra principle and critical crack opening criterion. The crack subcritical growth of a specific material is studied as an example __________ Translated from Prikladnaya Mekhanika, Vol. 43, No. 8, pp. 92–101, August 2007.     

Microvoid multistage nucleation model and its application in analysis of micro damage and fracture

In this paper, the microvoid multistage nucleation model [14,15] suggested by the authors of this paper has been studied on the micro ductile damage and fracture of metallic material under large elastic-plastic deformation.Using this model, the analyses of micro damage and fracture for various axisymmetric tensile specimens and for TPB and CCP cracked specimens have been carried out. And the results from these analyses on damage development and fracture are in good agreement with the experimental ones for axisymmetric specimens and reasonable for cracked specimens from the microscopic point of view.The project surported by National Science Foundations of China.