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.     

Fracture of bicrystal metal/ceramic interfaces: A study via the mechanism-based strain gradient crystal plasticity theory

Two continuum mechanical models of crystal plasticity theory namely, conventional crystal plasticity theory and mechanism-based crystal plasticity theory, are used to perform a comparative study of stresses that are reached at and ahead of the crack tip of a bicrystal niobium/alumina specimen. Finite element analyses are done for a stationary crack tip and growing cracks using a cohesive modelling approach. Using mechanism-based strain gradient crystal plasticity theory the stresses reached ahead of the crack tip are found to be two times larger than the stresses obtained from conventional crystal plasticity theory. Results also show that strain gradient effects strongly depend on the intrinsic material length to the size of plastic zone ratio (l/R₀). It is found that the larger the (l/R₀) ratio, the higher the stresses reached using mechanism-based strain gradient crystal plasticity theory. An insight into the role of cohesive strength and work of adhesion in macroscopic fracture is also presented which can be used by experimentalists to design better bimaterials by varying cohesive strength and work of adhesion.     

Modelling of laminated microstructures in stress-induced martensitic transformations

This paper is concerned with micromechanical modelling of stress-induced martensitic transformations in crystalline solids, with the focus on distinct elastic anisotropy of the phases and the associated redistribution of internal stresses. Micro-macro transition in stresses and strains is analysed for a laminated microstructure of austenite and martensite phases. Propagation of a phase transformation front is governed by a time-independent thermodynamic criterion. Plasticity-like macroscopic constitutive rate equations are derived in which the transformed volume fraction is incrementally related to the overall strain or stress. As an application, numerical simulations are performed for cubic β₁ (austenite) to orthorhombic γ₁′ (martensite) phase transformation in a single crystal of Cu-Al-Ni shape memory alloy. The pseudoelasticity effect in tension and compression is investigated along with the corresponding evolution of internal stresses and microstructure.     

Effect of source and obstacle strengths on yield stress: A discrete dislocation study

The combined effect of dislocation source strength τ_s, dislocation obstacle strength τ_obs, and obstacle spacing L_obs on the yield stress of single crystal metals is investigated analytically and numerically. A continuum theory of dislocation pileups emanating from a finite-strength source and impinging on asymmetric obstacles gives a closed-form expression for the yield stress. A 2d discrete dislocation model for a single-source/obstacle problem agrees well with the analytic model over a wide range of material parameters. Discrete dislocation simulations for a full tensile bar with statistically distributed sources and obstacles show that the distribution of obstacles plays a significant role in controlling the yield stress. Over a wide range of parameters, the simulations agree well with the analytic model using an effective obstacle spacing L_obs^* chosen to capture the strength-controlling statistically weaker pileup configurations. The analytic model can thus be used to guide the choice of source and obstacle parameters to obtain a desired yield stress. The model also shows how different combinations of internal source and obstacle parameters can generate the same macroscopic yield stress, and points to several internal length scales that could relate to size-dependent plasticity phenomena.     

Void growth and coalescence in single crystals

Void growth and coalescence in single crystals are investigated using crystal plasticity based 3D finite element calculations. A unit cell involving a single spherical void and fully periodic boundary conditions is deformed under constant macroscopic stress triaxiality. Simulations are performed for different values of the stress triaxiality, for different crystal orientations, and for low and high work-hardening capacity. Under low stress triaxiality, the void shape evolution, void growth, and strain at the onset of coalescence are strongly dependent on the crystal orientation, while under high stress triaxiality, only the void growth rate is affected by the crystal orientation. These effects lead to significant variations in the ductility defined as the strain at the onset of coalescence. An attempt is made to predict the onset of coalescence using two different versions of the Thomason void coalescence criterion, initially developed in the framework of isotropic perfect plasticity. The first version is based on a mean effective yield stress of the matrix and involves a fitting parameter to properly take into account material strain hardening. The second version of the Thomason criterion is based on a local value of the effective yield stress in the ligament between the voids, with no fitting parameter. The first version is accurate to within 20% relative error for most cases, and often more accurate. The second version provides the same level of accuracy except for one crystal orientation. Such a predictive coalescence criterion constitutes an important ingredient towards the development of a full constitutive model for porous single crystals.     

Stability of crystalline solids—I: Continuum and atomic lattice considerations

Many crystalline materials exhibit solid-to-solid martensitic phase transformations in response to certain changes in temperature or applied load. These martensitic transformations result from a change in the stability of the material's crystal structure. It is, therefore, desirable to have a detailed understanding of the possible modes through which a crystal structure may become unstable. The current work establishes the connections between three crystalline stability criteria: phonon-stability, homogenized-continuum-stability, and the presently introduced Cauchy-Born-stability criterion. Stability with respect to phonon perturbations, which probe all bounded perturbations of a uniformly deformed specimen under “hard-device” loading (i.e., all around displacement type boundary conditions) is hereby called “constrained material stability”. A more general “material stability” criterion, motivated by considering “soft” loading devices, is also introduced. This criterion considers, in addition to all bounded perturbations, all “quasi-uniform” perturbations (i.e., uniform deformations and internal atomic shifts) of a uniformly deformed specimen, and it is recommend as the relevant crystal stability criterion.     

Anisotropic yield criterion for polycrystalline metals using texture and crystal symmetries

An anisotropic yield criterion for polycrystalline metals which uses texture data and takes advantage of crystal symmetries is presented. A linear transformation is developed to map an anisotropic yield surface for a polycrystal to an appropriate isotropic yield surface. The transformation developed reflects the symmetry of the material being modeled. First, the transformation is determined. Then, information regarding the orientation distribution (texture) of the crystals in a polycrystalline aggregate is used to determine, via averaging, the transformation for the polycrystal. The transformation, along with appropriate isotropic yield surface, provides a phenomenological approach to modeling yield, yet accounts for microstructural texture. The approach reduces to the Hill (1950) anisotropic plasticity theory under certain conditions. The yield surfaces and R-values for various face-centered-cubic ( fcc) polycrystalline textures are computed by this method. Results compare favorably with those given by other theories, and with experiment. The method proves to have the computational efficiency of phenomenological approaches to modeling yield, while effectively incorporating the physics of more complex crystallographic approaches.     

Matched asymptotic expansions in nonlinear fracture mechanics—III. In-plane loading of an elastic perfectly-plastic symmetric specimen

The matched expansion method, introduced by the authors in two earlier papers (1976) devoted to mode III loading, is applied to the practically important case of mode I loading of a symmetric specimen. The method allows the linear elastic far-field to be considered separately from the elasto-plastic near-tip field, except for coupling through a set of parameters that are determined explicitly in the matching. The effects of the plasticity are thus found, once and for all, from the solution of a set of standard elasto-plastic problems for a semi-infinite crack in an infinite body, whose properties may be tabulated. The solution for any particular specimen geometry and loading then follows from a small set of linear elastic solutions for the specimen, which define, through coefficients γ_ij appearing in their near-tip expansions, all the parameters in the “inner” and “outer” solutions. The effects of plasticity appear in these parameters only through a set of constants C_ti that define the far-field expansions of the “inner” (near-tip) solutions: they are material constants, depending upon the constitutive relation for the material, but not upon specimen geometry and loading. The J-integral, being obtainable from the far-field, is expressed as an explicit asymptotic series in the loading parameter ε, whose coefficients are given as functions of the “elastic” parameters γ_ij and the material constants C_i. It is demonstrated that a plastic-zone correction term, r_y, can be chosen to yield a two-term asymptotic expansion for J; the value of r_y depends upon the yielding model only through the constant C₁.The Dugdale (1960) model of yielding is treated, as a simple example for which all calculations can be performed analytically, and for which exact solutions are available for comparison.Finally, the near-tip solutions are constructed for a material obeying the Mises yield criterion and associated flow-rule, using a specially developed finite element program. The first eight of the constants C_i are tabulated, which suffice to define the J-integral up to terms of order ε⁶ (where ε is a loading parameter) and some representative near-tip features are displayed graphically. The computed value of C₁ shows that the conventionally adopted value for the plastic-zone correction r_y is too large by a factor of roughly 2.8, if it is to yield a genuine asymptotic estimate for J. As an example, the “elastic” parameters γ_ij are found, from a boundary collocation program, for a centre-cracked square plate subjected to tensile loading; and a plot of J versus load, and the plastic-zone shape at a particular load level, are displayed.     

Dislocation-based micropolar single crystal plasticity: Comparison of multi- and single criterion theories

Two new formulations of micropolar single crystal plasticity are presented within a geometrically linear setting. The construction of yield criteria and flow rules for generalized continuum theories with higher-order stresses can be done in one of two ways: (i) a single criterion can be introduced in terms of a combined equivalent stress and inelastic rate or (ii) or individual criteria can be specified for each conjugate stress/inelastic kinematic rate pair, a so-called multi-criterion theory. Both single and multi-criterion theories are developed and discussed within the context of dislocation-based constitutive models. Parallels and distinctions are made between the proposed theories and some of the alternative generalized crystal plasticity models that can be found in the literature. Parametric numerical simulations of a constrained thin film subjected to simple shear are conducted via finite element analysis using a simplified 2-D version of the fully 3-D theory to highlight the influence of specific model components on the resulting deformation under both loading and unloading conditions. The deformation behavior is quantified in terms of the average stress-strain response and the local shear strain and geometrically necessary dislocation density distributions. It is demonstrated that micropolar single crystal plasticity can qualitatively capture the same range of behaviors as slip gradient-based models, while offering a simpler numerical implementation and without introducing plastic slip rates as generalized traction-conjugate velocities subject to an additional microforce balance.     

Analyses of steady quasistatic crack growth in plane strain tension in elastic-plastic materials with non-isotropic hardening

Steady state crack propagation problems of elastic-plastic materials in Mode I, plane strain under small scale yielding conditions were investigated with the aid of the finite element method. The elastic-perfectly plastic solution shows that elastic unloading wedges subtended by the crack tip in the plastic wake region do exist and that the stress state around the crack tip is similar to the modified Prandtl fan solution. To demonstrate the effects of a vertex on the yield surface, the small strain version of a phenomenological J₂, corner theory of plasticity (Christoffersen, J. and Hutchinson, J. W. J. Mech. Phys. Solids,27, 465 C 1979) with a power law stress strain relation was used to govern the strain hardening of the material. The results are compared with the conventional J₂ incremental plasticity solution. To take account of Bauschinger like effects caused by the stress history near the crack tip, a simple kinematic hardening rule with a bilinear stress strain relation was also studied. The results are again compared with the smooth yield surface isotropic hardening solution for the same stress strain curve. There appears to be more potential for steady state crack growth in the conventional J₂ incremental plasticity material than in the other two plasticity laws considered here if a crack opening displacement fracture criterion is used. However, a fracture criterion dependent on both stress and strain could lead to a contrary prediction.     

Failure prediction in anisotropic sheet metals under forming operations with consideration of rotating principal stretch directions

An approximate macroscopic yield criterion for anisotropic porous sheet metals is adopted to develop a failure prediction methodology that can be used to investigate the failure of sheet metals under forming operations. Hill's quadratic anisotropic yield criterion is used to describe the matrix normal anisotropy and planar isotropy. The approximate macroscopic anisotropic yield criterion is a function of the anisotropy parameter R, defined as the ratio of the transverse plastic strain rate to the through-thickness plastic strain rate under in-plane uniaxial loading conditions. The Marciniak–Kuczynski approach is employed here to predict failure/plastic localization by assuming a slightly higher void volume fraction inside randomly oriented imperfection bands in a material element of interest. The effects of the anisotropy parameter R, the material/geometric inhomogeneities, and the potential surface curvature on failure/plastic localization are first investigated. Then, a non-proportional deformation history including relative rotation of principal stretch directions is identified in a critical element of a mild steel sheet under a fender forming operation given as a benchmark problem in the 1993 NUMISHEET conference. Based on the failure prediction methodology, the failure of the critical sheet element is investigated under the non-proportional deformation history. The results show that the gradual rotation of principal stretch directions lowers the failure strains of the critical element under the given non-proportional deformation history.     

Crack separation energy-rates for the DBCS model under biaxial modes of loading

A Modified version of the Dugdale-Bilby-Cottrell-Swinden (DBCS) model simulating the effect of plasticity at the tip of a crack in an infinite region was used by kfouri and rice (1978) to calculate the crack separation energy-rate G^Δ corresponding to a finite crack growth step Δa during plane strain mode I crack extension. The loading consisted of a remote uniaxial tension σp applied normally to the plane of the crack. Using Rice's path-independent integral J to characterize the applied load in the crack tip region, and assuming the length R of the crack tip plastic zone to be small compared with the length of the crack, an analytical expression was derived relating the ratios (J/G^Δ) and (2a/R) for small values of (2a/R). The analytical solution was incomplete in itself in that the value assumed in the plastic region of the DBCS model for the normal stress Y acting on the extending crack surfaces was the product of the yield stress in uniaxial tension σ_Y and an unknown parameter C, the value of which depends on the effect of the local hydrostatic stresses in the case of plane strain conditions. The analytical solution was compared with a numerical solution obtained from a plane strain elastic-plastic finite element analysis on a centre-cracked plate (CCP) of material obeying the von Mises yield criterion. The value used for the yield stress was 310 MN/m² and moderate isotropic linear hardening was applied with a tangent modulus of 4830 MN/m². A uniaxial tension σp was applied on the two appropriate sides of the plate. The comparisons showed that the analytical and finite element solutions were mutually consistent and they enabled the value of C to be established at 1.91. In the present paper similar comparisons are made between the analytical solution and the finite element solutions for the CCP of the same material under different biaxial modes of loading. By assuming further that the form of the analytical solution does not depend on the details of the geometry and of the loading at remote boundaries, a comparison has also been made with the results of a finite element analysis on a compact tension specimen (CTS) made of the same material as the CCP. The different values of C obtained in each case are consistent with investigations by other authors on the effect of load biaxiality on crack tip plasticity.     

Décomposition de Kelvin et concept de contraintes effectives multiples pour les matériaux anisotropes

The effective stress concept, now classical in continuum damage mechanics, is generalized to the case of an initial anisotropy. In order to be used for both damage–elasticity and damage–(visco-)plasticity coupling, the effective stress should not depend on the elastic properties. Kelvin decomposition of the elasticity tensor allows to define such a stress for isotropic and cubic symmetries. For other material symmetries, the concept of multiple effective stresses is proposed. To cite this article: R. Desmorat, C. R. Mecanique 337 (2009).     

A texture based continuum approach for predicting the plastic behaviour of rolled sheet

A simple analytical model is proposed for predicting the plastic behaviour of orthotropic materials, considered as aggregates of cubic crystals. The behaviour of a single texture component is first described by a quadratic yield equation reduced to the case of cubic symmetry. A combination procedure of the components, using two different assumptions, is then presented. It turns out that the overall plasticity criterion is itself a Hill type quadratic equation, the associated orthotropy parameters of which are analytically derived. Comparison with experiment is carried out with results of the literature as well as direct measurements. Finally, the special case of axially symmetric materials is analyzed.     

Size effects in generalised continuum crystal plasticity for two-phase laminates

The solutions of a boundary value problem are explored for various classes of generalised crystal plasticity models including Cosserat, strain gradient and micromorphic crystal plasticity. The considered microstructure consists of a two-phase laminate containing a purely elastic and an elasto-plastic phase undergoing single or double slip. The local distributions of plastic slip, lattice rotation and stresses are derived when the microstructure is subjected to simple shear. The arising size effects are characterised by the overall extra back stress component resulting from the action of higher order stresses, a characteristic length l_c describing the size-dependent domain of material response, and by the corresponding scaling law lⁿ as a function of microstructural length scale, l. Explicit relations for these quantities are derived and compared for the different models. The conditions at the interface between the elastic and elasto-plastic phases are shown to play a major role in the solution. A range of material parameters is shown to exist for which the Cosserat and micromorphic approaches exhibit the same behaviour. The models display in general significantly different asymptotic regimes for small microstructural length scales. Scaling power laws with the exponent continuously ranging from 0 to −2 are obtained depending on the values of the material parameters. The unusual exponent value −2 is obtained for the strain gradient plasticity model, denoted “curl H^p” in this work. These results provide guidelines for the identification of higher order material parameters of crystal plasticity models from experimental data, such as precipitate size effects in precipitate strengthened alloys.     

准脆性材料的弹塑性各向异性损伤耦合本构模型研究

针对准脆性材料的非线性特征,在热动力学框架内,建立了准脆性材料的弹塑性与各向异性损伤耦合的本构关系.对准脆性材料的变形机理和损伤诱发的各向异性进行了诠释,并给出了损伤构形和有效构形中各物理量之间的关系.在有效应力空间内,建立了塑性屈服准则、拉压不同的塑性随动强化法则和各向同性强化法则.在损伤构形中,采用应变能释放率,建立了拉压损伤准则、拉压不同的损伤随动强化法则和各向同性强化法则.基于塑性屈服准则和损伤准则,构建了塑性势泛函和损伤势泛函,并由正交性法则,给出了塑性和损伤强化效应内变量的演化规律,同时,联立塑性屈服面和损伤加载面,给出了塑性流动和损伤演化内变量的演化法则.将损伤力学和塑性力学结合起来,建立了应变驱动的应力-应变增量本构关系,给出了本构数值积分的要点.以单轴加载-卸载往复试验识别和校准了材料常数,并对简单试验进行了预测,结果表明,所建本构模型对准脆件材料的非线性材料性能有良好的预测能力.