6061-T6铝合金动态拉伸本构关系及失效行为

采用HMH-206高速材料试验机开展了6061-T6铝合金在0.001～100 s-1应变率范围内的静、动态拉伸力学性能实验,分析了其应力-应变响应特征和应变率敏感性,讨论了应变率对6061-T6铝合金流动应力和应变率敏感性指数的影响,并基于实验结果对Johnson-Cook本构模型进行了修正。结合缺口试件的实验结果和模拟数据,得到了材料的Johnson-Cook失效模型参数,并对模型的准确性和适用性进行了验证。结果表明,在拉伸载荷作用下,6061-T6铝合金表现出明显的应变硬化特征和应变率敏感性,其流动应力随应变率的升高而提高,修正的Johnson-Cook本构模型可以描述材料的动态塑性流动行为,建立的Johnson-Cook失效模型能够表征材料的断裂失效行为。     

基于应力三轴度和罗德参数的6061和7075铝合金材料断裂失效分析

分别对6061铝合金和7075铝合金材料的缺口圆棒试件和凹槽平板试件进行准静态拉伸试验,并采用ABAQUS软件对拉伸过程进行数值模拟。模拟结果与试验测试结果吻合很好,验证了有限元模型的合理性和可靠性。通过有限元模拟,分别给出了不同试件的应力三轴度和罗德参数随等效塑性应变的变化曲线以及两种材料的失效轨迹,并对它们进行了分析讨论。结果表明:形状相同、材料性质不同的试件,应力三轴度的演化规律不同;材料的失效应变受应力三轴度和罗德参数的影响,并且不同性质的材料对罗德参数的敏感性不同。     

Effect of texture smearing on the anisotropy of cleavage-stress of metals and alloys

The effect of crystallographic texture smearing on the anisotropy of fracture stress of metals is analyzed. It is found that texture smearing leads to an appreciable decrease in the value of the coefficient of cleavage-stress anisotropy compared with that for metals with very sharp textures. The magnitude of this effect depends on the initial plastic strain (that depends on the breadth of texture component) and the level of stress triaxiality.     

Damage in edge cracking of rolled metal slabs

Materials get damaged under shear deformations. Edge cracking is one of the most serious damage to the metal rolling industry, which is caused by the shear damage process and the evolution of anisotropy. To investigate the physics of the edge cracking process, simulations of a shear deformation for an orthotropic plastic material are performed. To perform the simulation, this paper proposes an elasto-aniso-plastic constitutive model that takes into account the evolution of the orthotropic axes by using a bases rotation formula, which is based upon the slip process in the plastic deformation. It is found through the shear simulation that the void can grow in shear deformations due to the evolution of anisotropy and that stress triaxiality in shear deformations of (induced) anisotropic metals can develop as high as in the uniaxial tension deformation of isotropic materials, which increases void volume. This echoes the same physics found through a crystal plasticity based damage model that porosity evolves due to the grain-to-grain interaction. The evolution of stress components, stress triaxiality and the direction of the orthotropic axes in shear deformations are discussed.     

镁合金MB2在高应力三轴度下的拉伸破坏行为研究

通过光滑试件及不同曲率半径缺口圆柱试件的拉伸试验,实现对镁合金MB2的单向及多向应力状态加载。结合数值模拟分析,研究了不同试件在拉伸加载过程中应力状态的变化。以应力三轴度为参数,给出了镁合金MB2等效破坏应变的变化规律,在应力三轴度-等效破坏应变空间建立了镁合金MB2的失效破坏准则。利用扫描电镜对试件断口形貌进行观察,分析了导致材料宏观延性变化的微观损伤机理,对不同应力状态下镁合金MB2的失效破坏行为做出了合理解释。     

Void growth and coalescence in anisotropic plastic solids

Large strain finite element calculations of unit cells subjected to triaxial axisymmetric loadings are presented for plastically orthotropic materials containing a periodic distribution of aligned spheroidal voids. The spatial distribution of voids and the plastic flow properties of the matrix are assumed to respect transverse isotropy about the axis of symmetry of the imposed loading so that a two-dimensional axisymmetric analysis is adequate. The parameters varied pertain to load triaxiality, matrix anisotropy, initial porosity and initial void shape so as to include the limiting case of penny-shaped cracks. Attention is focussed on comparing the individual and coupled effects of void shape and material anisotropy on the effective stress–strain response and on the evolution of microstructural variables. In addition, the effect of matrix anisotropy on the mode of plastic flow localization is discussed. From the results, two distinct regimes of behavior are identified: (i) at high triaxialities, the effect of material anisotropy is found to be persistent, unlike that of initial void shape and (ii) at moderate triaxialities the influence of void shape is found to depend strongly on matrix anisotropy. The findings are interpreted in light of recent, microscopically informed models of porous metal plasticity. Conversely, observations are made in relation to the relevance of these results in the development and calibration of a broader set of continuum damage mechanics models.     

Influences of initial porosity,stress triaxiality and Lode parameter on plastic deformation and ductile fracture

Local mechanical properties in aluminum cast components are inhomogeneous as a consequence of spatial distribution of microstructure,e.g.,porosity,inclusions,grain size and arm spacing of secondary dendrites.In this work,the effect of porosity is investigated.Cast components contain voids with different sizes,forms,orientations and distributions.This is approximated by a porosity distribution in the following.The aim of this paper is to investigate the influence of initial porosity,stress triaxiality and Lode parameter on plastic deformation and ductile fracture.A micromechanical model with a spherical void located at the center of the matrix material,called the representative volume element(RVE),is developed.Fully periodic boundary conditions are applied to the RVE and the values of stress triaxiality and Lode parameter are kept constant during the entire course of loading.For this purpose,a multi-point constraint(MPC)user subroutine is developed to prescribe the loading.The results of the RVE model are used to establish the constitutive equations and to further investigate the influences of initial porosity,stress triaxiality and Lode parameter on elastic constant,plastic deformation and ductile fracture of an aluminum die casting alloy.     

Stability of boreholes in a geologic medium including the effects of anisotropy

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An analysis of ductile rupture in notched bars

Ductile fracture in axisymmetric and plane strain notched tensile specimens is analyzed numerically, based on a set of elastic-plastic constitutive relations that account for the nucleation and growth of microvoids. Final material failure by void coalescence is incorporated into the constitutive model via the dependence of the yield function on the void volume fraction. In the analyses the material has no voids initially; but as the voids nucleate and grow, the resultant dilatancy and pressure sensitivity of the macroscopic plastic flow influence the solution significantly. Considering both a blunt notch geometry and a sharp notch geometry in the computations permits a study of the relative roles of high strain and high triaxiality on failure. Comparison is made with published experimental results for notched tensile specimens of high-strength steels. All axisymmetric specimens analyzed fail at the center of the notched section, whereas failure initiation at the surface is found in plane strain specimens with sharp notches, in agreement with the experiments. The results for different specimens are used to investigate the circumstances under which fracture initiation can be represented by a single failure locus in a plot of stress triaxiality vs effective plastic strain.     

Numerical prediction of fracture in the Taylor test

A flat-nosed cylinder moving at a sufficiently high impact velocity in the classical Taylor test will always fracture. In this paper, fracture phenomena and fracture mechanisms in the Taylor test are investigated numerically based on a recently developed ductile fracture locus with the cut-off value for the negative stress triaxiality at −1/3. The impact velocity of the projectile ranges from 240 m/s to 600 m/s. The lower velocity is applied to a less ductile 2024-T351 aluminum alloy cylinder while the higher velocity is introduced for more ductile Weldox 460 E steel. Three distinct fracture modes are recreated numerically: the confined fracture inside the cylinder, the shear cracking on the lateral surface, and the petalling, all of which are consistent with experimental results presented in the open literature. It is found that a more ductile cylinder tends to fail by petalling while a less ductile one by shear cracking. Confined fracture is a common failure mode for both materials, which occurs in a wide range of the impact velocity. The ductile fracture criterion with the cut-off value predicts realistic fracture patterns for short cylinders deforming predominantly under compression.     

A Shear Compression Disk Specimen with Controlled Stress Triaxiality Under Dynamic Loading

This paper presents an experimental and numerical study of the potential of the Shear Compression Disk specimen (SCD) to characterize the plastic flow and fracture of metals under various levels of stress triaxiality at strain rates of up to 10⁴ 1/s. The main loading mode in that specimen is shear with triaxiality ranging from 0 to -0.8. The specimen is relatively small and fits into a standard split Hopkinson pressure bar system. Aluminum 7075-T651 alloy was chosen for a test case study. Experimental and numerical investigations reveal the adequacy of the SCD specimen for the study of mechanical properties of materials under high strain-rates and low, though wide, range of stress triaxialities.     

Tension–torsion fracture experiments—Part I: Experiments and a procedure to evaluate the equivalent plastic strain

Ductile failure experiments on a double notched tube (DNT) specimen subjected to a combination of tensile load and torque that was applied at a fixed ratio is presented. The experimental results extend those in Barsoum and Faleskog (2007a) down to zero stress triaxiality. A new and robust evaluation procedure for such tests is proposed, and a simple relation for the equivalent plastic strain at failure for combined normal and shear deformation, respectively, is developed. Tests were carried out on the medium strength medium hardening steel Weldox 420, and the high strength low hardening steel Weldox 960. The experimental results unanimously show that ductile failure not only depends on stress triaxiality, but is also strongly affected by the type of deviatoric stress state that prevails, which can be quantified by a stress invariant that discriminates between axisymmetric stressing and shear dominated stressing, e.g., the Lode parameter. Additional experiments on round notch bar (RNB) specimens are recapitulated in order to give a comprehensive account on how ductile failure depends on stress triaxiality, ranging from zero to more than 1.6, and the type of stress state for the two materials tested. This provides an extensive experimental data base that will be used to explore an extension of the Gurson model that incorporates damage development in shear presented in Xue et al. (2013) (Part II).     

Rupture mechanisms in combined tension and shear—Micromechanics

A micromechanics model based on the theoretical framework of plastic localization into a band introduced by Rice is developed. The model consists of a planar band with a square array of equally sized cells, with a spherical void located in the centre of each cell. The periodic arrangement of the cells allows the study of a single unit cell for which fully periodic boundary conditions are applied. The micromechanics model is applied to analyze failure by ductile rupture in experiments on double notched tube specimens subjected to combined tension and torsion carried out by the present authors. The stress state is characterized in terms of the stress triaxiality and the Lode parameter. Two rupture mechanisms can be identified, void coalescence by internal necking at high triaxiality and void coalescence by internal shearing at low triaxiality. For the internal necking mechanism, failure is assumed to occur when the deformation localizes into a planar band and is closely associated with extensive void growth until impingement of voids. For the internal shearing mechanism, a simple criterion based on the attainment of a critical value of shear deformation is utilized. The two failure criteria capture the transition between the two rupture mechanisms successfully and are in good agreement with the experimental result.     

镍基单晶合金多轴非比例加载低周疲劳研究

基于正交设计, 分别在680℃和850℃下进行DD3镍基单晶合金薄壁圆管试样([001]取向)拉/扭非比例加载低周疲劳试验, 研究等效应变范围、应变路径角、拉/扭载荷相位角、循环特性和温度诸因素对镍基单晶合金多轴低周疲劳寿命的影响作用. 疲劳试验数据的极差分析表明, 应变路径角、拉/扭载荷相位角和等效应变范围是影响疲劳寿命的主要因素. 将菱形应变加载路径区分为比例加载段和非比例加载段, 提出了表征非比例加载效应的等效应变参量, 并通过引入单晶应变三轴性因子反映拉/扭应变路径角对多轴疲劳寿命的影响. 用考虑非比例加载效应的等效应变范围和单晶应变三轴性因子构造循环塑性应变能损伤参量, 进行多元线性回归分析, 疲劳寿命回归模型与试验寿命具有很好的相关性, 所有试验数据都落在2.0倍的偏差分布带之内.      

Rupture mechanisms in combined tension and shear—Experiments

An experimental investigation of the rupture mechanisms in a mid-strength and a high-strength steel were conducted employing a novel test configuration. The specimen used was a double notched tube specimen loaded in combined tension and torsion at a fixed ratio. The effective plastic strain, the stress triaxiality and the Lode parameter were determined in the centre of the notch at failure. Scanning electron microscopy of the fractured surfaces revealed two distinctively different ductile rupture mechanisms depending on the stress state. At high stress triaxiality the fractured surfaces were covered with large and deep dimples, suggesting that growth and internal necking of voids being the governing rupture mechanism. At low triaxiality it was found that the fractured surfaces were covered with elongated small shear dimples, suggesting internal void shearing being the governing rupture mechanism. In the fractured surfaces of the high-strength steel, regions with quasi-cleavage were also observed. The transition from the internal necking mechanism to the internal shearing mechanism was accompanied by a significant drop in ductility.     

A selfconsistent formulation for the prediction of the anisotropic behavior of viscoplastic polycrystals with voids

In this work we consider the presence of ellipsoidal voids inside polycrystals subjected to large strain deformation. For this purpose, the originally incompressible viscoplastic selfconsistent (VPSC) formulation of Lebensohn and Tomé (Acta Metall. Mater. 41 (1993) 2611) has been extended to deal with compressible polycrystals. In doing this, both the deviatoric and the spherical components of strain-rate and stress are accounted for. Such an extended model allows us to account for the void and for porosity evolution, while preserving the anisotropy and crystallographic capabilities of the VPSC model. The formulation can be adjusted to match the Gurson model, in the limit of rate-independent isotropic media and spherical voids. We present several applications of this extended VPSC model, which address the coupling between texture, plastic anisotropy, void shape, triaxiality, and porosity evolution.     

Yield anisotropy effects on buckling of circular tubes under bending

Relatively thin-walled tubes bent into the plastic range buckle by axial wrinkling. The wrinkles initially grow stably but eventually localize and cause catastrophic failure in the form of sharp local kinking. The onset of axial wrinkling was previously established by bifurcation analyses that use instantaneous deformation theory moduli. The curvatures at bifurcation were predicted accurately, but the wrinkle wavelengths were consistently longer than measured values. The subject is revisited with the aim of resolving this discrepancy. A set of new bending experiments is conducted on aluminum alloy tubes. The results are shown to be in line with previous ones. However, the tubes used were found to exhibit plastic anisotropy, which was measured and characterized through Hill’s quadratic anisotropic yield function. The anisotropy was incorporated in the flow theory used for prebuckling and postbuckling calculations as well as in the deformation theory used for bifurcation checks. With the anisotropy accounted for, calculated tube responses are found to be in excellent agreement with the measured ones while the predicted bifurcation curvatures and wrinkle wavelengths fall in line with the measurements also. The postbuckling response is established using a finite element model of a tube assigned an initial axisymmetric imperfection with the calculated wavelength. The response develops a limit moment that is followed by a sharp kink that grows while the overall moment drops. The curvature at the limit moment agrees well with the experimental onset of failure. From parametric studies of the various instabilities it is concluded that, for optimum predictions, anisotropy must be incorporated in both bifurcation buckling as well as in postbuckling calculations.     

高分子材料平面应变拉伸变形局部化

将基于应变软化玻璃状高分子材料微观特征建立的ＢＰＡ８－链分子网络模型引入ＵｐｄａｔｉｎｇＬａｇｒａｎｇｅ有限元方法，建立了适于变形局部化分析的大变形弹塑性有限元驱动应力法．在此基础上，数值模拟了初始各向同性高分子材料平面应变拉伸变形局部化的传播过程．探讨了ＢＰＡ模型对具有加工硬化特性的结晶性高分子材料变形分析的适应性；分析了局部化传播过程中颈缩截面的非均匀应力三轴效应；最后，讨论了网格尺寸以及初始几何不均匀性对颈缩扩散以及应力三轴效应的影响     

钨合金弹体对混凝土靶的超高速侵彻机理

为研究钨合金弹体超高速侵彻混凝土靶的相关机理,构建了适用于超高速撞击的金属强度模型、失效模型和混凝土的本构模型,对93钨合金弹体超高速撞击混凝土靶问题进行了数值模拟。开展了钨合金弹体超高速撞击混凝土靶实验,分析了靶板成坑特性,研究了侵彻总深度和残余弹体长度随撞击速度的变化规律,理论分析了长杆钨弹超高速撞击混凝土的侵彻模型和混凝土靶内的应力波传播。得到以下主要结论:（1）利用金属及混凝土的新本构模型获得的超高速撞击混凝土靶的破坏形貌数值模拟结果与实验结果一致;（2）超高速撞击条件下混凝土靶成坑为“弹坑＋弹洞”形,成坑体积与弹体动能近似成正比;（3）超高速撞击条件下,侵彻深度随弹速提高呈现先增大后减小的现象,高速段侵深降低是弹体经历销蚀侵彻后“刚体侵彻阶段”减少造成的;（4）建立的钨合金超高速撞击混凝土侵彻分析模型,可用来预估侵彻深度、残余弹长、蘑菇头直径等参数;（5）采用建立的超高速撞击混凝土靶内应力波传播理论模型得到的计算结果与实验结果吻合较好。