Multiscale modelling of the plastic anisotropy and deformation texture of polycrystalline materials

A hierarchical multilevel method is presented for the plastic deformation of polycrystalline materials with texture-induced anisotropy. It is intended as a constitutive material model for finite element codes for the simulation of metal forming processes or for the prediction of forming limits. It consists of macroscopic models of which the parameters are to be identified using the results of two-level (meso/macro) or three-level (micro/meso/macro) models. A few such two-level models are presented, ranging from the full-constraints Taylor model to the crystal-plasticity finite element models, including the grain interaction models GIA, LAMEL and ALAMEL. Validation efforts based on experimental cold rolling textures obtained for steel and aluminium alloys are shortly discussed. An assessment is also given of the assumptions of the LAMEL and ALAMEL models concerning stress and strain rate heterogeneity at grain boundaries, based on the results of a crystal plasticity finite element study. Finally a recent three-level model which also looks at the microscopic level (dislocation substructure) is discussed.     

Micromechanical modelling of the static and cyclic loading of an Al 2124-SiC MMC

The objective of this study was to use micromechanical finite element models to simulate both the static and cyclic mechanical behaviour of a metal matrix composite: a forged Al 2124 alloy reinforced with 17% SiC particles, at two different temperatures: room temperature and 150°C. In the simulations, periodic unit cell models incorporating the explicit representation of the matrix and the reinforcing particles in both 2D and 3D, were used. Micromechanical models with both idealised and realistic reinforcing particle shapes and distributions were generated. The realistic particle shapes and distributions were inferred from experimental SEM micrographs. The pattern and intensity of the plastic deformation within the matrix was studied and the macroscale behaviour of the composite was inferred from average stress and strain values. In order to include the effects of residual stresses due to the processing of the material, a quenching simulation was performed, prior to the mechanical loading, and its effects on the macroscopic tensile behaviour of the MMC was assessed. The effects of removing the periodicity constraint on the models by using a cell embedding technique was investigated. In order to try and model the deformation behaviour of the matrix more accurately, crystal plasticity models, which included the explicit representation of individual grains were examined for different matrix grain morphologies. The results of the simulations were compared with experimental results for the MMC in terms of macroscopic tensile stress–strain curves. Finally, the effects of different matrix strain hardening models were examined in order to investigate the cyclic behaviour of the MMC.     

Elastic Deformation of Materials under Distributed Shear Loading

In this work, the deformation of material under localised tangential loading has been investigated. An analytical expression to predict deformation and strain patterns under tangential loading over a rectangular patch on a surface is validated against experiential tests using surface displacement measurement and finite element modelling. The predicted force- displacement data and displacement/strain patterns show close agreement with experimental results a rubber test material and FE results. The ranges of specimen geometries that minimise the boundary effects have been determined.     

Modelling and experimental characterisation of the Lüders strain in complex loaded ferritic steel compact tension specimens

The use of 3D digital image correlation (DIC) has been used to capture the Lüders strains in a low carbon ferritic steel. Results were used to calibrate and compare with finite element (FE) results based on a constitutive plasticity model, capable of yield drop behaviour and therefore Lüders strains, by Zhang et al. (2001). Tensile tests were carried out at several strain rates to characterise the material behaviour. The results of these tests were used to fit parameters in the constitutive plasticity model. The FE model was then tested on a complex loading situation of in-plane compression of a compact tension (CT) specimen. The FE model predicts the shape and formation of the Lüders bands well. This FE model, using Zhang’s constitutive plasticity model, was used to predict the residual stress profile to compare with standard elastic–plastic isotropic hardening models with no yield point. The yield point reduced both the predicted peak tensile stress, at the notch root, and the amount of plastic strain. In regions where the plastic strain was of a similar size to the Lüders strain the stress profiles were perturbed from flat profiles predicted by the standard elastic–plastic hardening models.     

基于试验与有限元耦合技术的延性材料全程单轴本构关系获取方法

摘 要: 材料拉伸直至断裂的全程单轴本构关系对材料大变形和断裂机理研究具有重要意义。传统拉伸试验获取的材料真应力-真应变曲线在试样颈缩后不可测。借助可以精确测量三维变形的DIC(Digital image correlate) 技术和有限元分析技术(Finite element analysis),本文提出了基于漏斗试样拉伸试验获取材料全程单轴本构关系的新方法,即TF(Test and FEA)方法。该方法将TF方法获取的材料全程单轴应力应变关系曲线作为有限元软件中的材料本构关系对漏斗试样拉伸变形过程进行模拟,其模拟载荷-位移曲线、漏斗根部直径-位移曲线和漏斗变形轮廓线等均与试验结果吻合良好,试样表面模拟应变也与DIC测试结果吻合, 根据不同半径漏斗试样模拟获得的全程真应力-真应变曲线保持良好一致性。最后,还对试样颈缩断面的力学行为进行了讨论,并给出了304不锈钢、汽轮机叶片材料2Cr12Ni4Mo3VNBN和 1Gr12Ni3Mo2VN、汽轮机转子材料30Cr2Ni4MoV的全程单轴本构关系模型参数、破断应力和破断应变。     

On the evolution of lattice deformation in austenitic stainless steels—The role of work hardening at finite strains

In this work, a three dimensional crystal plasticity-based finite element model is presented to examine the micromechanical behaviour of austenitic stainless steels. The model accounts for realistic polycrystal micromorphology, the kinematics of crystallographic slip, lattice rotation, slip interaction (latent hardening) and geometric distortion at finite deformation. We utilise the model to predict the microscopic lattice strain evolution of austenitic stainless steels during uniaxial tension at ambient temperature with validation through in situ neutron diffraction measurements. Overall, the predicted lattice strains are in very good agreement with those measured in both longitudinal and transverse directions (parallel and perpendicular to the tensile loading axis, respectively). The information provided by the model suggests that the observed nonlinear response in the transverse {200} grain family is associated with a competitive bimodal evolution of strain during inelastic deformation. The results associated with latent hardening effects at the microscale also indicate that in situ neutron diffraction measurements in conjunction with macroscopic uniaxial tensile data may be used to calibrate crystal plasticity models for the prediction of the inelastic material deformation response.     

考虑晶体滑移面分解正应力的细观损伤模型

材料内部的解理、滑移面剥离等细观损伤是引起宏观失效的根源,从细观尺度研究损伤的发生和发展有助于深入认识材料的变形和失效过程.本文基于晶体塑性理论,从滑移系的受力和变形出发研究材料的细观损伤,建立了考虑滑移面分解正应力的细观损伤模型,为晶体材料解理断裂的分析提供了新方法.首先,在晶体弹塑性变形构型的基础上引入损伤变形梯度...     

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.     

用于高强度材料的SHPB实验添加垫块法

提出了用于高强度材料的改进的SHPB实验方法添加垫块法,运用数值模拟方法,利用有限元程序LS-DYNA3D分析了添加垫块实验方法的合理性和可行性。根据一维应力波理论,给出了数据处理的修正方法。作为应用实例,采用改进的实验方法对高强度的Al2O3陶瓷材料的动态力学性能进行了研究,得到了比常规方法较高的应变率及应力应变范围的动态应力应变曲线,表明Al2O3陶瓷为应变率相关的非线性弹脆性材料。结果表明,添加垫块实验方法可有效地防止实验中压杆端面的变形,提高试件的应力应变及应变率水平。添加垫块实验方法为在SHPB装置上实现高强度材料的动态实验提供了一种方便实用的途径。     

A stochastic model for the temporal aspects of flow intermittency in micropillar compression

Systematic experimental investigations have demonstrated that the plastic deformation of micropillar proceeds through a sequence of intermittent bursts, the sizes of which follow power-law statistics. In this study, a stochastic model based on the power-law distribution of burst size is formulated in the framework of crystal plasticity in order to investigate the temporal aspects of flow intermittency in micropillar compression. A Monte Carlo simulation scheme is developed to determine the burst size when a burst activity is captured. This burst size is considered as the displacement boundary condition of burst deformation. Three-dimensional finite element analysis of the model is performed and its predictions are validated by comparison with results from both micro-compression experiments and simulation tests of bulk crystals using the classic crystal plasticity finite element method (CPFEM). The model provides a reasonable prediction of stress–strain responses both at the macroscopic and microscopic scales. Finally, the capability of this model is shown with applications to the intermittent plastic deformation in micropillar compressions, in particular for their burst time durations and burst velocities. The results from such stochastic finite element analysis are shown to be consistent with earlier experimental findings and results of mean-field theory.     

受轴向冲击薄壁圆管的几何畸变相似律研究

对于受轴向冲击载荷作用的薄壁圆管动态响应的相似律问题,由于圆管的薄壁特性导致厚度无法与高度和半径按相同的比例进行结构缩放,从而产生模型的几何畸变,此时传统的相似律已无法描述原型与畸变模型之间的动态响应规律。基于薄壁圆管轴向冲击问题的控制方程,通过能量守恒和量纲分析,推导了考虑几何畸变条件下轴向冲击载荷作用的理想弹塑性薄壁圆管动态响应的相似律。通过在给定应变与应变率区间上建立比例模型预测的流动屈服应力与原型流动屈服应力的最佳逼近关系,将几何畸变相似律进一步推广至包含应变率和应变硬化的材料。通过数值方法验证了提出的几何畸变模型相似律的适用性。分析结果表明,提出的考虑厚度畸变的受轴向冲击薄壁圆管的相似律可用于预测原型结构的冲击动态响应,并显著降低比例模型与原型结构平均载荷和能量的偏差。     

Design of microstructure-sensitive properties in elasto-viscoplastic polycrystals using multi-scale homogenization

Evolution of properties during processing of materials depends on the underlying material microstructure. A finite element homogenization approach is presented for calculating the evolution of macro-scale properties during processing of microstructures. A mathematically rigorous sensitivity analysis of homogenization is presented that is used to identify optimal forging rates in processes that would lead to a desired microstructure response. Macro-scale parameters such as forging rates are linked with microstructure deformation using boundary conditions drawn from the theory of multi-scale homogenization. Homogenized stresses at the macro-scale are obtained through volume-averaging laws. A constitutive framework for thermo-elastic–viscoplastic response of single crystals is utilized along with a fully-implicit Lagrangian finite element algorithm for modelling microstructure evolution. The continuum sensitivity method (CSM) used for designing processes involves differentiation of the governing field equations of homogenization with respect to the processing parameters and development of the weak forms for the corresponding sensitivity equations that are solved using finite element analysis. The sensitivity of the deformation field within the microstructure is exactly defined and an averaging principle is developed to compute the sensitivity of homogenized stresses at the macro-scale due to perturbations in the process parameters. Computed sensitivities are used within a gradient-based optimization framework for controlling the response of the microstructure. Development of texture and stress–strain response in 2D and 3D FCC aluminum polycrystalline aggregates using the homogenization algorithm is compared with both Taylor-based simulations and published experimental results. Processing parameters that would lead to a desired equivalent stress–strain curve in a sample poly-crystalline microstructure are identified for single and two-stage loading using the design algorithm.     

Hybrid experimental–numerical analysis of basic ductile fracture experiments for sheet metals

A basic ductile fracture testing program is carried out on specimens extracted from TRIP780 steel sheets including tensile specimens with a central hole and circular notches. In addition, equi-biaxial punch tests are performed. The surface strain fields are measured using two- and three-dimensional digital image correlation. Due to the localization of plastic deformation during the testing of the tensile specimens, finite element simulations are performed of each test to obtain the stress and strain histories at the material point where fracture initiates. Error estimates are made based on the differences between the predicted and measured local strains. The results from the testing of tensile specimens with a central hole as well as from punch tests show that equivalent strains of more than 0.8 can be achieved at approximately constant stress triaxialities to fracture of about 0.3 and 0.66, respectively. The error analysis demonstrates that both the equivalent plastic strain and the stress triaxiality are very sensitive to uncertainties in the experimental measurements and the numerical model assumptions. The results from computations with very fine solid element meshes agree well with the experiments when the strain hardening is identified from experiments up to very large strains.     

An interfacial energy incorporated couple stress crystal plasticity and the finite element simulation of grain subdivision

A couple stress crystal plasticity formulation that incorporates interfacial couple stress energy was proposed in terms of the virtual work-rate principle for finite element method. By applying the assumed constitutive models of couple stress at the grain boundary as well as the grain interior, finite element simulations were conducted for various crystal models, with different grain subdivision models to examine how plastic deformation work is affected by grain subdivision from the interfacial couple stress energy effect.Finite element simulation results showed that the amount of predicted plastic deformation work depends on grain subdivision, and that the amount of work can be minimized for a particular grain subdivision. We inferred from the simulation results that actual grain subdivision might correspond to the minimum amount of plastic deformation work and, if this correlation is validated, actual grain subdivision might be predicted based on the interfacial energy incorporated couple stress crystal plasticity.     

Strain gradient effects on microscopic strain field in a metal matrix composite

The purpose of this paper is to demonstrate the improved modeling accuracy of a finite-deformation strain gradient crystal plasticity formulation over its classical counterpart by conducting a joint experimental and numerical investigation of the microscopic details of the deformation of a whisker-reinforced metal-matrix composite. The lattice rotation distribution around whiskers is obtained in thin foils using a TEM technique and is then correlated with numerical predictions based on finite element analyses of a unit-cell of a single crystal matrix containing a rigid whisker. The matrix material is first characterized by a classical, scale-independent crystal plasticity theory. It is found that the classical theory predicts a lattice rotation distribution with a spatial gradient much higher than experimentally measured. A strain gradient crystal plasticity formulation is then applied to model the matrix. The strain gradient formulation accounts for both strain hardening and strain gradient hardening. The deformation thus predicted exhibits a strong dependence on the size of the whisker. For a constitutive length scale comparable to the whisker diameter, the spatial gradient of the lattice rotation is several times lower than that predicted by the classical theory, and hence correlates significantly better with the experimental results.     

Unified elastoplastic finite difference and its application

Two elastoplastic constitutive models based on the unified strength theory (UST) are established and implemented in an explicit finite difference code, fast Lagrangian analysis of continua (FLAC/FLAC3D), which includes an associated/non-associated flow rule, strain-hardening/softening, and solutions of singularities. Those two constitutive models are appropriate for metallic and strength-different (SD) materials, respectively. Two verification examples are used to compare the computation results and test data using the two-dimensional finite difference code FLAC and the finite element code ANSYS, and the two constitutive models proposed in this paper are verified. Two application examples, the large deformation of a prismatic bar and the strain-softening behavior of soft rock under a complex stress state, are analyzed using the three-dimensional code FLAC3D. The two new elastoplastic constitutive models proposed in this paper can be used in bearing capacity evaluation or stability analysis of structures built of metallic or SD materials. The effect of the intermediate principal stress on metallic or SD material structures under complex stress states, including large deformation, three-dimensional and non-association problems, can be analyzed easily using the two constitutive models proposed in this paper.     

Calibrating a J2 plasticity material model using a 2D inverse finite element procedure

Material models are the key ingredients to accurately capture the global mechanical response of structural systems. The use of finite element analysis has proven to be effective in simulating nonlinear engineering applications. However, the choice of the appropriate material model plays a big role in the value of the numerical predictions. Such models are not expected to exactly reproduce global experimental response in all cases. Alternatively, the measured global response at specific domain or surface points can be used to guide the nonlinear analysis to successively extract a representative material model. By selecting an initial set of stress–strain data points, the load–displacement response at the monitoring points is computed in a forward incremental analysis without iterations. This analysis retains the stresses at the integration points. The corresponding strains are not accurate since the computed displacements are not anticipated to match the measured displacements at the monitoring points. Therefore, a corrective incremental displacement analysis is performed at the same load steps to adjust for displacements and strains everywhere by matching the measured displacements at the monitoring points. The stress–strain vectors at the most highly stressed integration point are found to establish an improved material model. This model is used within a multi-pass incremental nonlinear finite element analysis until the discrepancy between the measured and the predicted structural response at the monitoring points vanishes. The J2 flow theory of plasticity is used as a constitutive framework to build the tangent elastic–plastic matrices. The applicability of the proposed approach is demonstrated by solving 2D inverse continuum problems. The comparisons presented support the effectiveness of the proposed approach in accurately calibrating the J2 plasticity material model for such problems.     

正交各向异性韧性材料应力-应变关系

采用大变形弹塑性有限元方法分析了各向同性和正交各向异性韧性材料光滑圆棒拉伸试件的颈缩问题．首先给出了采用计算机模拟确定各向同性韧性材料真实应力-应变曲线的具体方法；对正交各向异性韧性材料的分析表明，颈缩截面呈椭圆形，其长短轴方向的等效塑性应变基本上均匀分布，与Bridgman假设一致；轴向拉伸载荷-位移曲线与其它两方向的各向异性参数关系不大．在此基础上，建议了一种确定正交各向异性韧性材料真实应力-应变曲线的方法．