Identification of Mechanical Material Behavior Through Inverse Modeling and DIC

Inverse methods offer a powerful tool for the identification of the elasto-plastic material parameters. One of the advantages with respect to classical material testing is the fact that those inverse methods are able to deal with heterogeneous deformation fields. The basic principle of the inverse method that is presented in this paper, is the comparison between experimentally measured strain fields and those computed by the finite element (FE) method. The unknown material parameters in the FE model are iteratively tuned so as to match the experimentally measured and the numerically computed strain fields as closely as possible. This paper describes the application of an inverse method for the identification of the hardening behavior and the yield locus of DC06 steel, based on a biaxial tensile test on a perforated cruciform specimen. The hardening behavior is described by a Swift type hardening law and the yield locus is modeled with a Hill 1948 yield surface.     

Identification of material parameters for inelastic constitutive models: Stochastic simulations for the analysis of deviations

For parameter identification a distance function between the measured and the simulated data has to be minimized. Therefore, the influence of three different norms used in the definition of such a distance function is investigated. The nonlinear optimization problem is solved using a modified random search algorithm originally proposed by Price (1978). Next a stochastic model for the generation of artificial test data is presented. This model is used for a stochastic simulation of test data (constant strain rate tension with relaxation and creep). From these artificial data the material parameters of the model of Chan, Bodner and Lindholm are identified. To measure the quality of the identified material parameters their mean values and empirical standard deviations are computed. Furthermore, the coefficients of the empirical correlation matrix for the material parameters are computed. The model responses for tensile tests with the parameter vector generated from all tests and with the estimated parameters (from stochastic simulations) differ not considerably. However, for the creep tests the different parameter estimations lead to quite different model responses. Received October 22, 1999     

Analysis of the strain field in the vicinity of a crack-tip in an in-plane isotropic paper material

Strains, computed by the finite element method, are evaluated and compared to an experimentally determined strain field. The analyzed low-density paper has been designed to ensure bond–breakage as the dominating damage mechanism and the paper material is approximately in-plane isotropic. An optical non-contact displacement measuring system has been used in fracture tests to determine the strain field in the crack-tip region of a pre-fabricated crack. Additionally, acoustic emission monitored tensile tests have been conducted to determine onset and evolution of damage processes and thereby enabling calibration of required constitutive parameters. The results suggest that the investigated paper material can tolerate significantly higher strains than what is predicted by a classic elastic–plastic J₂-flow theory. Immediately before onset of the final fracture (i.e., localization), the experimental measured normal strain in the near-tip region is around 60% higher than the computed strain when using exclusively an elastic–plastic theory for the corresponding load while the strain computed utilizing a non-local damage theory is of the same order of magnitude as the experimentally measured strain. Hence, it seems essential to include a non-local continuum theory to describe strains in the near-tip region quantitatively correct for paper materials. It is demonstrated that path independence of the well-known J-integral does not prevail for this class of material models. Only for the special situation of a homogenous damage field in the crack-tip region may the stress and strain fields be described by the well-known HRR-solutions.     

Modelling of the blanking process of high-carbon steel using Lemaitre damage model

This paper presents a methodology to model a blanking process using a continuum mechanical damage model. A variant of the Lemaitre model, in which the quasi-unilateral conditions are taken into consideration to modify the damage behavior under compressive stress states, is selected as material model. S45C high-carbon steel is analyzed experimentally. To characterize the damage behavior of the material, notched round bar tensile tests with three different notch radii (6 mm, 10 mm, and 20 mm) using image analysis are performed. Using digital image processing, the strain at the deformation zone can be computed for the load–strain curves. Those curves are used as an objective function to determine the parameters of the Lemaitre damage model. The experimental results are compared with the results of the FE analysis of the tensile test. The identified model parameters are used in numerical investigations of axisymmetric blanking. The effect of the model's extension to quasi-unilateral damage evolution is discussed. The crack progress in high-carbon steel sheet during blanking and the final sheared part morphology are predicted and compared with the experimental results. Sheared surface and burr height obtained by the analysis coincide with the results of the blanking experiment.     

Bammann-Chiesa-Johnson粘塑性本构模型材料参数的一种识别方法

粘塑性本构模型能否成功模拟金属高应变率大应变变形过程依赖于材料参数识别结果的好坏。由于BCJ模型考虑了应变率、温度与材料硬化之间的耦合效应以及应变率、温度历史效应,同时模型中包含了多个材料参数,因此很难通过试验直接识别模型的材料参数。本文针对BCJ模型中的耦合效应和历史效应,基于对模型中材料参数物理涵义的界定,给出了一种对材料参数解耦、分离并进行估计的方法,获得了模型材料参数估计公式,估计了材料参数的取值范围。在此基础上,编制了BCJ模型应力积分径向返回算法和粒子群优化算法的计算程序,应用重新设计了BCJ模型耦合效应和历史效应的反分析方法,在参数取值范围内对材料参数进行了优化识别。以OFHC Cu为例,应用提出的识别方法对BCJ模型的材料参数进行了识别,计算结果和试验结果符合较好。     

Parameter identification for cracks in elastic plate structures based on remote strain fields

A method for the detection of cracks in plate structures is presented. In contrast to most of the common monitoring concepts taking advantage of the reflection of elastic waves at crack faces, the presented approach is based on the strain measured at different locations on the surface of the structure. This allows both the identification of crack position parameters, such as length, location and angles with respect to a reference coordinate system and the calculation of stress intensity factors (SIF). The solution of the direct problem is performed on the basis of the BFM (body force method). The inverse problem is solved applying the particle swarm optimization (PSO) algorithm. The BFM is based on the principle of linear superposition which allows the calculation of the strain field in a cracked body. The strain at an arbitrary point in the structure is replaced by the strain provided by body force doublets in the uncracked structure. The doublets as well as external loads are parameters which have to be determined solving the inverse problem by minimizing a fitness function, which is defined by a square sum of residuals between measured strain distributions and computed ones for an assumed crack. The PSO algorithm applied to the fitness function operates on the basis of a swarm of candidate solutions. Once knowing loading and crack parameters, the SIF can be determined.     

Planar Strain Measurements on Wood Specimens

Wood specimens have been tested for compressive loading in the longitudinal direction. Planar deformation was recorded by means of video extensometry on the specimen surfaces. A post processing routine was developed to calculate stress and strain values from the sampled data. The routine made use of mathematical framework used in the finite element method. Material parameters were detected by means of an optimization algorithm, and the determined linear elastic parameters were in general found to be in good agreement with values given in literature. The utilized method offers simultaneous average values for active, passive and shear strains from the measured area. Moduli of elasticity, Poisson’s ratios and shear deformation can thus be evaluated. In addition, the variation of the three strain components over the area is measured. The results can therefore be used for quantification of material inhomogeneity and are further suitable for direct comparison with numerically computed strains comprising non-uniform strain fields. Since video extensometry does not require any physical contact with the specimen, measurements can be undertaken until failure. The present method offers thus an efficient and relatively accurate way to measure and evaluate the material characteristics of anisotropic and inhomogeneous materials like wood.     

Mixed numerical–experimental technique for orthotropic parameter identification using biaxial tensile tests on cruciform specimens

This paper presents a mixed numerical–experimental method for the identification of the four in-plane orthotropic engineering constants of composite plate materials. A biaxial tensile test is performed on a cruciform test specimen. The heterogeneous displacement field is observed by a CCD camera and measured by a digital image correlation (DIC) technique. The measured displacement field and the subsequently computed strain field are compared with a finite element simulation of the same experiment. The four independent engineering constants are unknown parameters in the finite element model. Starting from an initial value, these parameters are updated till the computed strain field matches the experimental strain field. Two specimen geometries are used: one with a centered hole to increase the strain heterogeneity and one without a hole. It is found that the non-perforated specimen yields the most accurate results.     

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.     

Design sensitivity analysis for parameters affecting geometry,elastic–viscoplastic material constant and boundary condition by consistent tangent operator-based boundary element method

This paper presents a design sensitivity analysis method by the consistent tangent operator concept-based boundary element implicit algorithm. The design variables for sensitivity analysis include geometry parameters, elastic–viscoplastic material parameters and boundary condition parameters. Based on small strain theory, Perzyna’s elastic–viscoplastic material constitutive relation with a mixed hardening model and two flow functions is considered in the sensitivity analysis. The related elastic–viscoplastic radial return algorithm and the formula of elastic–viscoplastic consistent tangent operator are derived and discussed. Based on the direct differentiation approach, the incremental boundary integral equations and related algorithms for both geometric and elastic–viscoplastic sensitivity analysis are developed. A 2D boundary element program for geometry sensitivity, elastic–viscoplastic material constant sensitivity and boundary condition sensitivity has been developed. Comparison and discussion with the results of this paper, analytical solution and finite element code ANSYS for four plane strain numerical examples are presented finally.     

SENSITIVITY ANALYSIS AND OPTIMIZATION OF COUPLED THERMAL AND FLOW PROBLEMS WITH APPLICATIONS TO CONTRACTION DESIGN

The finite element method and the Newton–Raphson solution algorithm are combined to solve the momentum, mass and energy conservation equations for coupled flow problems. Design sensitivities for a generalised response function with respect to design parameters which describe shape, material property and load data are evaluated via the direct differentiation method. The efficiently computed sensitivities are verified by comparison with computationally intensive, finite difference sensitivity approximations. The design sensitivities are then used in a numerical optimization algorithm to minimize the pressure drop in flow through contractions. Both laminar and turbulent flows are considered. In the turbulent flow problems the time-averaged momentum and mass conservati on equations are solved using a mixing length turbulence model.     

A Study of Large Plastic Deformations in Dual Phase Steel Using Digital Image Correlation and FE Analysis

Large plastic deformation in sheets made of dual phase steel DP800 is studied experimentally and numerically. Shear testing is applied to obtain large plastic strains in sheet metals without strain localisation. In the experiments, full-field displacement measurements are carried out by means of digital image correlation, and based on these measurements the strain field of the deformed specimen is calculated. In the numerical analyses, an elastoplastic constitutive model with isotropic hardening and the Cockcroft–Latham fracture criterion is adopted to predict the observed behaviour. The strain hardening parameters are obtained from a standard uniaxial tensile test for small and moderate strains, while the shear test is used to determine the strain hardening for large strains and to calibrate the fracture criterion. Finite Element (FE) calculations with shell and brick elements are performed using the non-linear FE code LS–DYNA. The local strains in the shear zone and the nominal shear stress-elongation characteristics obtained by experiments and FE simulations are compared, and, in general, good agreement is obtained. It is demonstrated how the strain hardening at large strains and the Cockcroft–Latham fracture criterion can be calibrated from the in-plane shear test with the aid of non-linear FE analyses. An erratum to this article can be found at     

Direct Extraction of Cohesive Fracture Properties from Digital Image Correlation: A Hybrid Inverse Technique

The accuracy of an adopted cohesive zone model (CZM) can affect the simulated fracture response significantly. The CZM has been usually obtained using global experimental response, e.g., load versus either crack opening displacement or load-line displacement. Apparently, deduction of a local material property from a global response does not provide full confidence of the adopted model. The difficulties are: (1) fundamentally, stress cannot be measured directly and the cohesive stress distribution is non-uniform; (2) accurate measurement of the full crack profile (crack opening displacement at every point) is experimentally difficult to obtain. An attractive feature of digital image correlation (DIC) is that it allows relatively accurate measurement of the whole displacement field on a flat surface. It has been utilized to measure the mode I traction-separation relation. A hybrid inverse method based on combined use of DIC and finite element method is used in this study to compute the cohesive properties of a ductile adhesive, Devcon Plastic Welder II, and a quasi-brittle plastic, G-10/FR4 Garolite. Fracture tests were conducted on single edge-notched beam specimens (SENB) under four-point bending. A full-field DIC algorithm was employed to compute the smooth and continuous displacement field, which is then used as input to a finite element model for inverse analysis through an optimization procedure. The unknown CZM is constructed using a flexible B-spline without any “a priori” assumption on the shape. The inversely computed CZMs for both materials yield consistent results. Finally, the computed CZMs are verified through fracture simulation, which shows good experimental agreement.     

Parameter determination and response analysis of viscoelastic material

The parameter determination of viscoelastic material is a multi-variable, multi-aim nonlinear optimization problem, which made the optimization process very complicated. In this paper a hybrid optimal algorithm was proposed to determine the viscoelastic parameters in the constitutive relation according to the experimentally obtained mechanical properties. This algorithm merges the Broydon–Fletcher–Goldfarb–Shanno search into a genetic algorithm framework as a basic operator in order to enhance the local search capability. The proposed hybrid algorithm not only can reduce the iterative times greatly but can abolish the limitation of initial parameter values. Nonlinear material characteristic curve-fitting was carried out using the proposed algorithm and other existing approaches. And the comparison results show this algorithm is accurate and effective. The numerical simulation and experimental study of viscoelastic cantilever beam also indicates that the finite element formulation and the calculative viscoelastic model parameters are reliable. The proposed optimization method can be extended to further complex parameter estimation researches.     

基于模态缩减和模态实验数据的结构连接参数识别方法

利用在结构系统可测自由度上获得的不完备模态参数和子结构的有限元模型，根据模态缩减理论，建立了识别子结构间连接子结构参数的优化模型，采用逐次二次规划法求解，改善了测试噪声和模态截断误差的影响。该方法识别精度高、收敛速度快、计算量小，便于工程应用。     

Statistical aspects of the identification of material parameters for elasto-plastic models

Summary The presented method to identify material parameters for inelastic deformation laws is based on the numerical analysis of inhomogeneous stress and strain fields received from suitable experiments. Tensile and bending tests were carried out to obtain elastic and hardening parameters. The deformation law for small elasto-plastic strains is presented as a system of nonlinear differential and algebraic equations (DAE) consisting of the stress–strain relation, evolution equations for the internal variables and the yield condition. Different rules for the evolution equations of isotropic, kinematic and distorsional hardening are proposed. The DAE are discretized using an implicit Euler method, and the resulting system of nonlinear algebraic equations is solved using the Newton method. Deterministic optimization procedures are preferred to identify material parameters from a least-squares functional of numerical and measured comparative quantities. The gradient of the objective function was calculated using a semianalytical sensitivity analysis. Due to measurement errors, the optimal sets of material parameters are non unique. The approximate estimation of confidence regions and the calculation of correlation coefficients is presented. The results of several optimization processes for material parameters of elasto-plastic deformation laws show a good agreement between measured and calculated values, but they show also problems which may occur if systematic errors will not be recognized and deleted. Received 30 September 1999; accepted for publication 8 March 2000     

Finite element modeling of tube hydroforming of polycrystalline aluminum alloy extrusions

Finite element modeling of tube hydroforming requires information about the anisotropy of the extruded aluminum tube. Unlike sheet metals, the complex geometry of extruded tubes makes it difficult, except in extrusion direction, to directly measure material properties. Therefore, polycrystalline models provide a good alternative for calculating the anisotropy of the tube in all directions and under various loading conditions. Using a rate-independent single crystal yield surface and rigid plasticity, a Taylor-type polycrystalline model was developed and implemented into ABAQUS/Explicit finite element (FE) code using VUMAT. The constitutive model was then used to calculate the crystallographic texture evolution during the hydroforming of an extruded aluminum tube. Initial crystallographic texture measured using orientation imaging microscopy (OIM) and uniaxial tensile test data obtained along the extrusion direction were input to this FEA model. In order to efficiently and practically simulate the tube hydroforming process using the polycrystalline model, sensitivity to the number of grain orientation, total simulation time, and number of finite elements were studied. Predicted results agreed very well with experimentally measured strain obtained from tube hydroforming process.     

Continuum-Based Shape Sensitivity Analysis for 2D Coupled Atomistic/Continuum Simulations Using Bridging Scale Decomposition

In this paper, we propose the first attempt to perform shape sensitivity analysis for two-dimensional coupled atomistic and continuum problems using bridging scale decomposition. Based on a continuum variational formulation of the bridging scale, the sensitivity expressions are derived in a continuum setting using both direct differentiation method and adjoint variable method. To overcome the issue of discontinuity in shape design due to the discrete nature of the molecular dynamics (MD) simulation, we define design velocity fields in a way that the shape of the MD region does not change. Another major challenge is that the discrete finite element (FE) mass matrix in bridging scale is not continuous with respect to shape design variables. To address this issue, we assume an evenly distributed mass density when evaluating the material derivative of the FE mass matrix. In order to support accuracy verification of sensitivity results using overall finite difference method, we use regular-shaped finite elements and only allow shape change in one direction in our example problems, so that design perturbations can be made to the discrete FE mass matrix. However, the sensitivity formulation is sufficiently general to support irregular-shaped finite elements and arbitrary design velocity fields. The sensitivity analysis results, verified using overall finite difference method, reveal the impact of macroscopic shape design changes on microscopic atomistic responses.     

Non-linear finite element analysis of cone penetration in layered sandy loam soil – Considering precompression stress state

Axisymmetric finite element (FE) method was developed to simulate cone penetration process in layered granular soil. The FE was modeled using ABAQUS/Explicit, a commercially available package. Soil was considered as a non-linear elastic plastic material which was modeled using variable elastic parameters of Young’s Modulus and Poisson’s ratio and Drucker–Prager criterion with yield stress dependent material hardening property. The material hardening parameters of the model were estimated from the USDA-ARS National Soil Dynamics Laboratory – Auburn University (NSDL-AU) soil compaction model. The stress–strain relationship in the NSDLAU compaction model was modified to account for the different soil moisture conditions and the influence of precompression stress states of the soil layers. A surface contact pair (‘slave-master’) algorithm in ABAQUS/Explicit was used to simulate the insertion of a rigid cone (RAX2 ABAQUS element) into deformable and layered soil medium (CAX4R ABAQUS element). The FE formulation was verified using cone penetration data collected on a soil chamber of Norfolk sandy loam soil which was prepared in two compaction treatments that varied in bulk density in the hardpan layer of (1) 1.64 Mg m⁻³ and (2) 1.71 Mg m⁻³. The FE model successfully simulated the trend of cone penetration in layered soils indicating the location of the sub-soil compacted (hardpan) layer and peak cone penetration resistance. Modification of the NSDL-AU model to account for the actual soil moisture content and inclusion of the influence of precompression stress into the strain behavior of the NSDL-AU model improved the performance of FE in predicting the peak cone penetration resistance. Modification of the NSDL-AU model resulted in an improvement of about 42% in the finite element-predicted soil cone penetration forces compared with the FE results that used the NSDL-AU ‘virgin’ model.