Shakedown analysis of engineering structures with limited kinematical hardening

We present a numerical method for the computation of shakedown loads of engineering structures with limited kinematical hardening under thermo-mechanical loading. The method is based on Melan’s statical shakedown theorem, which results in a nonlinear convex optimization problem. This is solved by an interior-point algorithm recently developed by the authors, specially designed for lower bound shakedown analysis of large-scale problems. Limited kinematical hardening is taken into account by use of a two-surface model, such that both alternating plasticity and incremental collapse can be captured. For the yield surface as well as for the bounding surface the von Mises criterion is used. The proposed method is validated by two examples, where numerical results are compared to those of literature where available.     

Mode II stress intensity factors for a crack parallel to the surface of an elastic half-space subjected to a moving point load

The direction of propagation of rolling contact fatigue cracks is observed to depend upon the direction of motion of the load. In this paper approximate calculations are described of the variation of Mode II stress intensity factors at each tip of a subsurface crack, which lies parallel to the surface of an elastic half-space, due to a load moving over the surface. In particular the effect of frictional locking of the crack faces under the load is investigated. In consequence of frictional locking the range of SIF at the trailing tip ΔK_T is found to be about 30% greater than that of the leading tip ΔK_L, which is consistent with observations that subsurface cracks propagate predominantly in the direction of motion of the load over the surface. The effects on k_t and k_lof crack length, crack face friction, traction forces at the surface and residual shear stresses are also investigated.     

Rolling contact of a rigid sphere/sliding of a spherical indenter upon a viscoelastic half-space containing an ellipsoidal inhomogeneity

In this paper, the frictionless rolling contact problem between a rigid sphere and a viscoelastic half-space containing one elastic inhomogeneity is solved. The problem is equivalent to the frictionless sliding of a spherical tip over a viscoelastic body. The inhomogeneity may be of spherical or ellipsoidal shape, the later being of any orientation relatively to the contact surface. The model presented here is three dimensional and based on semi-analytical methods. In order to take into account the viscoelastic aspect of the problem, contact equations are discretized in the spatial and temporal dimensions. The frictionless rolling of the sphere, assumed rigid here for the sake of simplicity, is taken into account by translating the subsurface viscoelastic fields related to the contact problem. Eshelby's formalism is applied at each step of the temporal discretization to account for the effect of the inhomogeneity on the contact pressure distribution, subsurface stresses, rolling friction and the resulting torque. A Conjugate Gradient Method and the Fast Fourier Transforms are used to reduce the computation cost. The model is validated by a finite element model of a rigid sphere rolling upon a homogeneous vciscoelastic half-space, as well as through comparison with reference solutions from the literature. A parametric analysis of the effect of elastic properties and geometrical features of the inhomogeneity is performed. Transient and steady-state solutions are obtained. Numerical results about the contact pressure distribution, the deformed surface geometry, the apparent friction coefficient as well as subsurface stresses are presented, with or without heterogeneous inclusion.     

Shakedown of a cohesive-frictional half-space subjected to rolling and sliding contact

The problem of rolling and sliding contact of a cylinder on the surface of a half-space of cohesive-frictional material is considered. Three shakedown multipliers, of which two are upper bounds and one is exact are computed using a simple numerical procedure. This latter solution differs significantly from previously published analytical solutions which, for realistic material parameters, typically overestimate the shakedown load by a factor of 1.5–2.5.     

SIMPLE SHAKEDOWN OF STRUCTURES UNDER VARIABLE MULTI-LOADINGS

The shakedown analysis of structures under variable multi-loadings is considered, and the corresponding simple shakedown condition is presented in this paper. Distribution of fixed stresses field is given, and the self-equilibrium of fixed stresses field is analyzed. Elastic shakedown and plastic shakedown conditions are presented based on the fixed stresses field. The theorem is convenient to evaluate the shakedown limit of structures under cyclical variable multiloadings through solving positive scalar fields and fixed stresses field factors at a series of dangerous positions of the structure, and tedious computations are avoided. Finally the theorem is applied to a thick-walled cylindrical tube under variable pressure and temperature, and the rolling contact problem. The results are in good agreement with some computational results.     

钢轨短波波磨的产生机理

通过对轮-轨系统进行动力学分析,指出高频率的能量传播主要集中于轮轨之间,在对轮-轨系统进行有限元分析的基础上,研究了轨道的受力情况和摩擦系数对应力分布的影响。讨论了轨道的弹塑变形和安定极限。     

Surface integrity of inconel-718 nickel-base superalloy using controlled and natural contact length tools. part I: Lubricated

The surface integrity of inconel-718 nickel-base superalloy was investigated using orthogonal cutting at various cutting speeds, depths of cut and chip-tool contact lengths under lubricated conditions. The experimental work involved the determination of residual stress, plastic strain and microhardness distribution in the surface region and the examination of the surface and subsurface using scanning electron and optical microscopy. Both residual stresses and plastic strains decreased and the quality of the mechined surface improved with an increase in cutting speed, a decrease in depth of cut and with tools having controlled chip-tool contact lengths. The results were interpreted in terms of the variation in shear plane length and consequently the variation in tool forces with cutting conditions.     

Thermal stresses and shakedown in wheel/rail contact

Summary  Sliding friction between railway wheels and rails results in considerable contact temperatures and gives rise to severe thermal stresses at the surfaces of the wheels and rails. An approximate analytical solution is presented for a line contact model. The increased bulk temperature of the wheel after a long period of constant operating conditions is also taken into account. The thermal stresses have to be superimposed on the mechanical contact stresses. They reduce the elastic limit of the wheel and rail, and yielding begins at lower mechanical loads. When residual stresses build up during the initial cycles of plastic deformation, the structure can carry higher loads with a purely elastic response in subsequent load cycles. This phenomenon is referred to as shakedown. Due to the distribution of temperature, the rail surface is generally subjected to higher stresses than the wheel surface. This can cause structural changes in the rail material and hence rail damage. Received 7 May 2002; accepted for publication 3 September 2002     

An Improved Upper Bound to Maximum Deflections of Elastic-Plastic Structures at Shakedown

ABSTRACT

A method is presented providing an upper bound to the maximum shakedown deflections for elastic-perfectly plastic structures. The influence of plastic zones is taken into account. Residual stresses required by the Melan theorem can be expressed in terms of stresses due to ideal plastic hinges and of stresses due to the finite extent of plastic zones. Making use of this fact a bound on the total energy dissipated in a shakedown process as well as a bound to the permanent displacement have been derived. This bound permits an estimate of the deflections at shakedown. Application of the method is illustrated by means of two examples.     

Adhesion-induced instabilities in elastic and elastic-plastic contacts during single and repetitive normal loading

Adhesive interaction in spherical contacts was modeled with the Lennard-Jones (L-J) potential. Elastic adhesive contact was analyzed by the equivalent system of a rigid sphere with reduced radius of curvature and a half-space of effective elastic modulus. The critical gap at the instant of abrupt surface contact (jump-in) and separation (jump-out) was determined from the deformed surface profile of the elastic half-space and geometrical relationships. A finite element model of a rigid sphere and an elastic-plastic half-space was used to examine elastic-plastic adhesive contact. Surface adhesion was modeled by nonlinear springs with a force-displacement relationship governed by the L-J potential. The evolution of the interfacial force and the central gap distance as well as the occurrence of jump-in and jump-out instabilities were investigated in terms of the Tabor parameter, plasticity parameter, and dimensionless maximum normal displacement. The force-displacement response due to several approach-retraction cycles was interpreted in the context of elastic and plastic shakedown behaviors using dimensionless parameters.     

Bounds for shakedown of cohesive-frictional materials under moving surface loads

In this paper, shakedown of a cohesive-frictional half space subjected to moving surface loads is investigated using Melan’s static shakedown theorem. The material in the half space is modelled as a Mohr–Coulomb medium. The sliding and rolling contact between a roller and the half space is assumed to be plane strain and can be approximated by a trapezoidal as well as a Hertzian load distribution. A closed form solution to the elastic stress field for the trapezoidal contact is derived, and is then used for the shakedown analysis. It is demonstrated that, by relaxing either the equilibrium or the yield constraints (or both) on the residual stress field, the shakedown analysis leads to various bounds for the elastic shakedown limit. The differences among the various shakedown load factors are quantitatively compared, and the influence of both Hertzian and trapezoidal contacts for the half space under moving surface loads is studied. The various bounds and shakedown limits obtained in the paper serve as useful benchmarks for future numerical shakedown analysis, and also provide a valuable reference for the safe design of pavements.     

Interfacial slip and creep in rolling contact incorporating a cylinder with an elastic layer

A systematic approach for investigating the interfacial behaviour of tyred systems is proposed. A two-dimensional contact model of an elastic strip, shrink-fitted onto a wheel, and subjected to different rolling contact conditions, has been adopted to illustrate the method. The model combines existing techniques to explore individual elastic contact problems and it enables us to characterise the behaviour at the strip/substrate interface caused by loads induced by a quasi-static application of stationary and moving loads on the surface of the layer. The solution is compared to the stationary load case and regimes of local slip, full stick, separation and frictional creep are identified and collated for a variety of loading conditions, materials and geometries. Further, this article presents an investigation of frictional shakedown for layered systems subjected to periodic contact loading. The term shakedown is here referred to as the possibility of developing interfacial residual stresses at the layer/substrate interface such that frictional slip, originally activated by the applied external contact load, ceases after a few loading cycles. The possible applicability of the Melan’s theorem for elastic frictional system is investigated and preliminary results presented.     

变曲率连续滚滑接触安定性的数值方法研究

针对接触表面变曲率的特点,引入局部坐标系,构造出局部坐标下残余应力应变场的分布状态,建立了变曲率连续啮合过程中安定状态残余应力的计算方法。该数值方法将弹塑性问题分解为弹性问题和特征应变决定的残余问题,并采用增量映射方法求解特征应变决定的残余问题,可直接得到接触安定状态下的接触残余应力,并随之进行安定极限的判定。采用该数值方法计算了不同曲率处接触点的安定极限,给出了安定极限与摩擦因数之间的关系,并与有关数值结果相比较,验证了该算法的有效性。     

基于正交基无单元Galerkin法和非线性规划的安定分析方法

基于安定分析的下限定理,用正交基无单元Galerkin法建立了交交载荷作用下理想弹塑性结构安定分析的下限计算格式.在给定载荷域的载荷角点所对应的载荷作用下,采用正交基无单元Galerkin法计算相应的虚拟弹性应力场.并且利用结构在正交基无单元Galerkin法弹塑性增量分析中平衡迭代结果计算得到自平衡应力场基矢量,然后由这些基矢量的线性组合模拟自平街应力场.安定分析问题最终被归结为一系列未知变量较少的非线性数学规划子问题,通过复合形法求解.算例表明该方法的计算结果是令人满意的,并且对初始复合形顶点和用于构造自平衡应力场基矢量的载荷增量是非常不敏感的.     

A kinematic elastic nonshakedown theorem for implicit standard materials

Summary  Criteria for a priori recognition of the type of steady-state response induced by cyclic loads and prediction whether a structure will shakedown elastically or not, without the necessity of performing a step-by-step full analysis, have considerable importance. Melan and Koiter theorems provide criteria that guarantee whether elastic shakedown occurs or not under cyclic loads in case of perfect plasticity. However, there remain some aspects of the shakedown theory which deserve further study. One of these, concerned with more realistic nonassociative elastic–plastic constitutive material models, allowing for nonlinear kinematic and isotropic hardening suitable to describe the cyclic plastic behaviour of metallic materials, has strong motivation. Koiter's elastic nonshakedown theorem is reconsidered here, with the objective of extending it to the de Saxcé's implicit standard material class, which contains a wide class of nonassociative elastic–plastic material behaviours. Shakedown analysis is formulated by a kinematic approach based on the plastic accumulation mechanism concept due to Polizzotto. A sufficient condition for elastic nonshakedown and a distinct necessary condition are established. Then, an upper bound to the shakedown multiplier is evaluated. Received 15 February 2001; accepted for publication 18 October 2001     

Fast evaluation of friction forces in traction-drive contacts including thermal effects

Summary  In automotive traction drives, power is transmitted by friction forces. The friction forces result from the shear stresses developed in lubricated and highly loaded contacts between rolling bodies. Due to the kinematics of a traction drive, shear velocities occur in both the rolling direction and perpendicular to it. Due to these shear velocities and by normal pressure, the lubricant is forced to build up shear stresses. The increase of the shear stresses may be modelled by a nonlinear viscous element. The describing differential equations are coupled by the equivalent shear stress, which defines the nonlinear behaviour of the element. A fast method is described to evaluate the coupled differential equations. By using a known analytical approximation for the equivalent shear stress, the differential equations are decoupled and can be solved analytically. In an iterative procedure the equivalent shear stress is updated, and the complete solution is found. The iterative method is extended to account for thermal effects in the contact. Received 17 June 1999; accepted for publication 26 October 1999     

Modeling elasto-plastic indentation on layered materials using the equivalent inclusion method

This paper develops a fast semi-analytical model for solving the three-dimensional elasto-plastic contact problems involving layered materials using the Equivalent Inclusion Method (EIM). The analytical elastic solutions of a half-space subjected to a unit surface pressure and a unit subsurface eigenstrain are employed in this model; the topmost layer is simulated by an equivalent inclusion with fictitious eigenstrain. Accumulative plastic deformation is determined by a procedure involving an iterative plasticity loop and an incremental loading process. Algorithms of the fast Fourier transform (FFT) and the Conjugate Gradient Method (CGM) are utilized to improve the computation efficiency. An analytical elastic solution of layered body contact (O’Sullivan and King, 1988) and an indentation experiment result involving a layered substrate (Michler et al., 1999) are used to examine the accuracy of this model. Comparisons between numerical results from the present model and a commercial FEM software (Abaqus) are also presented. Case studies of a rigid ball loaded against a layered elasto-plastic half-space are conducted to explore the effects of the modulus, yield strength, and thickness of the coating on the hardness, stiffness, and plastic deformation of the composite body.     

结构安定分析的Galerkin边界元方法

基于Melan静力安定定理,利用Galerkin边界元方法建立了多组交变载荷作用下结构安定分析的下限计算格式.在给定载荷域的载荷角点所对应载荷作用下,采用Galerkin边界元法计算相应的虚拟弹性应力场,并且利用结构在Galerkin边界元弹塑性增量计算中同一增量步中不同迭代步之间的应力差作为自平衡应力场的基矢量,通过这些基矢量的线性组合构造了自平衡应力场,大大降低了所形成的数学规划问题的未知变量数.并通过复合形法对非线性规划问题直接进行求解,得到了结构在交变载荷作用下的下限安定乘子.计算结果表明,所采用的方法具有较高的精度和计算效率.     

Shakedown limits for an oscillating,elastic rolling contact with Coulomb friction

We examine experimentally and theoretically the effect of frictional shakedown of a three-dimensional elastic rolling contact. Small oscillations of the local normal forces lead to incremental sliding processes within the area of contact. Consequently, this causes a macroscopic slip motion of the two contacting bodies. If the oscillation amplitude is sufficiently small, the frictional slip ceases after the first few loading periods and a safe shakedown occurs. Otherwise the slip motion is continued and the contact fails.     

钢轨短波长波浪形磨损的安定性分析

针对轮-轨滚动接触的短波长波浪形磨损现象,采用有限元法分析了三维实体模型的接触状态,通过计算分析了高频力作用下接触表面的塑性变形过程.结果表明:在一定的运动条件下,由于重复滚压作用,接触表面发生硬化并达到安定极限状态,生成有规律的短波长变形;钢轨表面塑性变形受枕木间距的影响;就具有随动硬化特性的钢轨材料而言,当摩擦系数μ<0.3时,屈服现象发生在材料表层下方;随着摩擦系数的增大,接触表面的切向力增大,安定极限的临界接触压力Po降低,屈服点移向接触表面,材料失效加快.