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.     

Numerical simulation of elasto-plastic deformation of composites: evolution of stress microfields and implications for homogenization models

The deformation of a composite made up of a random and homogeneous dispersion of elastic spheres in an elasto-plastic matrix was simulated by the finite element analysis of three-dimensional multiparticle cubic cells with periodic boundary conditions. “Exact” results (to a few percent) in tension and shear were determined by averaging 12 stress-strain curves obtained from cells containing 30 spheres, and they were compared with the predictions of secant homogenization models. In addition, the numerical simulations supplied detailed information of the stress microfields, which was used to ascertain the accuracy and the limitations of the homogenization models to include the nonlinear deformation of the matrix. It was found that secant approximations based on the volume-averaged second-order moment of the matrix stress tensor, combined with a highly accurate linear homogenization model, provided excellent predictions of the composite response when the matrix strain hardening rate was high. This was not the case, however, in composites which exhibited marked plastic strain localization in the matrix. The analysis of the evolution of the matrix stresses revealed that better predictions of the composite behavior can be obtained with new homogenization models which capture the essential differences in the stress carried by the elastic and plastic regions in the matrix at the onset of plastic deformation.     

The predicted compressive strength of a pyramidal lattice made from case hardened steel tubes

A sandwich panel with a core made from solid pyramidal struts is a promising candidate for multifunctional application such as combined structural and heat-exchange function. This study explores the performance enhancement by making use of hollow struts, and examines the elevation in the plastic buckling strength by either strain hardening or case hardening. Finite element simulations are performed to quantify these enhancements. Also, the sensitivity of competing collapse modes to tube geometry and to the depth of case hardening is determined. A comparison with other lattice materials reveals that the pyramidal lattice made from case hardened steel tubes outperforms lattices made from solid struts of aluminium or titanium and has a comparable strength to a core made from carbon fibre reinforced polymers.     

Micromechanics, macromechanics and constitutive modeling of the elasto-viscoplastic deformation of rubber-toughened glassy polymers

Under certain conditions, such as sufficiently low temperatures, high loading rates and/or highly triaxial stress states, glassy polymers display an unfavorable characteristic—brittleness. A technique used for reducing the brittleness (increasing the fracture toughness) of these materials is rubber toughening. While there is significant qualitative understanding of the mechanical behavior of rubber-toughened polymers, quantitative modeling tools for the large-strain deformation of rubber-toughened glassy polymers are largely lacking.In this paper, we develop a suite of numerical tools to investigate the mechanical behavior of rubber-toughened glassy polymers, with emphasis on rubber-toughened polycarbonate. The rubber particles are modeled as voids in view of their deformation-induced cavitation early during deformation. A three-dimensional micromechanical model of the heterogeneous microstructure is developed to study the effects of initial rubber particle (void) volume fraction on the underlying elasto-viscoplastic deformation mechanisms in the material, and how these mechanisms influence the macroscopic response of the material. A continuum-level constitutive model is developed for the large-strain elasto-viscoplastic deformation of porous glassy polymers, and it is calibrated against micromechanical modeling results for porous polycarbonate. The constitutive model can be used to study various boundary value problems involving rubber-toughened (porous) glassy polymers. As an example, the case of an axisymmetric notched bar is simulated for the case of polycarbonate with varying levels of initial porosity. The quality of the constitutive model calibration is assessed using a multi-scale modeling approach.     

On the modeling of evolving anisotropy and large strains in pearlitic steel

A phenomenological model for deformation induced evolution of anisotropy at large strains in pearlitic steel is proposed. The modeled anisotropy is based on a homogenization of an ideal pearlitic microstructure. An areal affine type of reorientation is assumed for the individual grains. Furthermore, a yield criterion of the Hill type is proposed and motivated from the grain reorientation. In each pearlitic grain the cementite lamellas have a privileged direction. The symmetry group of each individual grain is therefore considered transversally isotropic. In a virgin material, the privileged directions of the different grains are randomly oriented, which allows for the interpretation that the material on the macroscopic length scale is initially isotropic. However, the cementite lamellas in the grains tend to align after large stretching or shearing deformation. The modeled evolution of anisotropy on the macroscopic length scale shows a saturation characteristics under large deformations.     

Experimental investigation on martensitic transformation and fracture morphologies of austenitic stainless steel

Formation and nucleation mechanisms (i.e. γ → ε, γ → α′, γ → deformation twins → ε → α′ and γ → ε → α′) of deformation- induced martensite (DIM) have been studied through analytical transmission electron microscopy (TEM) after tensile deformation of AISI 304LN stainless steel at various strain rates (SR) at room temperature (RT). Quantitative metallography has been employed extensively to assess martensitic transformation (MT) as function of strain and SR. It has been observed that the enhancement of SR during tensile deformation promotes the early formation of DIM, while suppressing its saturation value at fracture. Fracture surface morphologies and dimple geometries (i.e. dimple density, dimple diameter and dimple size distribution) have been quantified through image processing (IP) of tensile fractographs. It is noted that at lower SR, dimple density is high while dimple diameter is smaller, and vice versa. Concomitantly, the strength is noted to be low and ductility is high at lower SR, and vice versa. DIM has been found to be responsible for high dimple density at low SR. At high SR, MT is suppressed and hence low dimple density. The variation in SR dependent MT accounts for the variation in dimple metrics vis-à-vis tensile properties.     

圆形中空夹层钢管超高性能钢纤维混凝土柱抗爆性能野外实验与数值模拟

通过6根圆形中空夹层钢管超高性能钢纤维混凝土(UHPSFRCFDST)柱爆炸破坏实验,研究了轴压、折合距离、空心率和迎爆面形状对其动态响应及损伤破坏的影响,并运用LS-DYNA软件建立了爆炸荷载作用下UHPSFRCFDST柱动态响应的有限元模型。在验证了模型有效性的基础上,运用参数化分析方法,研究了轴压比、空心率、含钢率、内层和外层钢管径厚比及其强度等关键参数对圆形UHPSFRCFDST柱抗爆性能的影响。结果表明:有限元模型能够有效地分析UHPSFRCFDST柱在爆炸荷载作用下的动态响应及损伤破坏;在小于临界轴压时,提高轴压比能够提升UHPSFRCFDST柱抗爆性能,但超过临界轴压后继续提高反而会加重其损伤破坏;减小空心率或内、外层钢管径厚比均可有效提升UHPSFRCFDST柱的抗爆性能,提高含钢率或外层钢管强度也能达到相同效果,但提高内层钢管强度对其抗爆性能的提升作用并不显著。     

Large deformation of anisotropic austenitic stainless steel sheets at room temperature: Multi-axial experiments and phenomenological modeling

A newly developed multi-axial testing technique for sheet materials is employed to investigate the inelastic response of a temper-rolled stainless steel 301LN under isothermal quasi-static loading conditions at room temperature. The experimental technique consists of a flat sheet specimen, which is subject to combinations of shear and normal loading using a custom-made dual-actuator system. The large deformation behavior under monotonic loading is determined along more than 20 distinct radial paths in the stress space. The experimental results indicate that Hill's quadratic yield function along with an associated flow rule provides a good approximation of the initial yield behavior of this anisotropic two-phase FCC/BCC sheet material. Based on the experimental data for radial monotonic loading, it is concluded that conventional isotropic-kinematic hardening models cannot successfully describe the strain hardening of this austenitic steel. Instead, a non-associated anisotropic hardening model is proposed that relates the increase in yield strength to an isothermal martensitic transformation kinetics law. The comparison of the model predictions with the experimental results shows very good agreement for all biaxial and uniaxial experiments.     

Numerical Simulation of Nanoindentation and Patch Clamp Experiments on Mechanosensitive Channels of Large Conductance in <Emphasis Type="Italic">Escherichia coli</Emphasis>

A hierarchical simulation framework that integrates information from all-atom simulations into a finite element model at the continuum level is established to study the mechanical response of a mechanosensitive channel of large conductance (MscL) in bacteria Escherichia coli (E. coli) embedded in a vesicle formed by the dipalmitoylphosphatidycholine (DPPC) lipid bilayer. Sufficient structural details of the protein are built into the continuum model, with key parameters and material properties derived from molecular mechanics simulations. The multi-scale framework is used to analyze the gating of MscL when the lipid vesicle is subjective to nanoindentation and patch clamp experiments, and the detailed structural transitions of the protein are obtained explicitly as a function of external load; it is currently impossible to derive such information based solely on all-atom simulations. The gating pathways of E. coli-MscL qualitatively agree with results from previous patch clamp experiments. The gating mechanisms under complex indentation-induced deformation are also predicted. This versatile hierarchical multi-scale framework may be further extended to study the mechanical behaviors of cells and biomolecules, as well as to guide and stimulate biomechanics experiments.     

粘塑性损伤模型模拟准超塑性单轴拉伸行为

发展了Chaboche粘塑性本构模型的大变形隐式算法，用损伤(DM)和无损伤(NDM)模型模拟准超塑性单轴拉伸。发现变形过程可分为三个阶段：均匀变形、颈缩发展、断裂破坏阶段。DM可准确模拟前两个阶段变形，NDM只能较好地模拟均匀变形阶段，表明DM可以较精确地描述稳定发展的动态过程。由于有限元方法只能描述连续介质，因此对于断裂破坏阶段，NDM模拟载荷大于试验结果，DM的载荷小于试验结果，这是由高应变速率敏感性造成。DM能够描述试验中出现地多处颈缩现象，局部应变速率分布随时间演化反映了颈缩发展程度。严重颈缩部位的距离代表着超塑性变形能力，距离越大，抗颈缩能力越好。     

超弹性形状记忆合金管单向拉伸试验的数值模拟

NiTi形状记忆合金具有很强的超弹性行为,这种超弹性行为是由于材料在应力作用下发生可逆的马氏体相变所引起。最近Sun和Lee^[4]在NiTi形状记忆合金管单向拉伸试验中观测到,应力诱导马氏体相变具有螺旋带状的形貌特征,本文对此作了数值模拟研究。采用包含应变软化效应的三线性本构关系,建立了NiTi形状记忆合金管的三维有限元模型。通过迭代计算,成功地再现了试验中所观察到的螺旋状相变带从形成到长大的全过程。数值计算结果表明,产生这一独特现象的力学机制,在于NiTi形状记忆合金管在拉伸状态下出现的局部变形失稳极其传播。     

On the uniaxial compression behavior of regular shaped cellular metals

The numerical simulation of random cellular metals is still connected to many unsolved problems due to their stochastic structure. Therefore, a periodic model of a cellular metal is developed for fundamental studies of the mechanical behavior and is numerically investigated under uniaxial compression. The influence of differing hardening behaviors and differing boundary conditions on the characteristics of the material is investigated. Recommendations for the numerical simulation are derived. In contrast to common models, experimental samples of the same geometry are easy to manufacture and the results of the experiments show good agreement with the finite element calculations. Based on the proposed concept of a unit cell with periodic boundary conditions, it is possible to derive constitutive equations of cellular materials under complex loading conditions.     

A method for reconstruction of residual stress fields from measurements made in an incompatible region

A method is introduced by which the complete state of residual stress in an elastic body may be inferred from a limited set of experimental measurements. Two techniques for carrying out this reconstruction using finite element analysis are compared and it is shown that for exact reconstruction of the stress field via this method, the stress field must be measured over all eigenstrain-containing regions of the object. The effects of error and incompleteness in the measured part of the stress field on the subsequent analysis are investigated in a series of numerical experiments using synthetic measurement data based on the NeT TG1 round-robin weld specimen. It is hence shown that accurate residual stress field reconstruction is possible using measurement data of a quality achievable using current experimental techniques.     

滑移爆轰驱动钢管的层裂

将VG损伤模型推广到二维情况,考虑了最大主应力方向对损伤演化的影响,并使用显式断裂算法对20钢管在GI-920炸药滑移爆轰驱动下层裂的问题进行二维数值模拟。分析了一维内爆和滑移爆轰两种加载方式下作用于钢管外表面的压力及钢管内部受力状态的区别,考察了滑移爆轰加载方式下钢管外表面的受力随炸药厚度变化的规律,进而研究了钢管内损伤的分布和演化,以及裂纹的产生和扩展现象。计算得到的层裂片初始厚度随炸药厚度的变化规律与实验结果符合较好。     

Crystal plasticity finite element modeling of mechanically induced martensitic transformation (MIMT) in metastable austenite

A new crystal plasticity model incorporating the mechanically induced martensitic transformation in metastable austenitic steel has been formulated and implemented into the finite element analysis. The kinetics of martensite transformation is modeled by taking into consideration of a nucleation-controlled phenomenon, where each potential martensitic variant based on Kurdjumov–Sachs (KS) relationship has different nucleation probability as a function of the interaction energy between externally applied stress and lattice deformation. Therefore, the transformed volume fractions are determined following selective variants given by the crystallographic orientation of austenitic matrix and applied stress in the frame of the crystal plasticity finite element. The developed finite element program is capable of considering the effect of volume change by the Bain deformation and the lattice-invariant shear during the martensitic transformation by effectively modifying the evolution of plastic deformation gradient of the conventional rate-dependent crystal plasticity finite element. The validation of the proposed model has been carried out by comparing with the experimentally measured data under simple loading conditions. Good agreements with the measurements for the stress–strain responses, transformed martensitic volume fractions and the influence of strain rate on the deformation behavior will enable the model to be promising for the future applications to the real forming process of the TRIP aided steel.     

颅脑正面碰撞的有限元模拟分析

利用人体脑部的CT图像,建立了一个基于人体解剖学结构的脑部的三维有限元模型.模型生物材料特性分别采用线弹性和粘弹性模型描述.在专业碰撞分析软件PAM-CRASH中,利用建成的颅脑三维有限元模型模拟正面颅脑碰撞过程,得到了碰撞过程的能量、速度、加速度、应力曲线和各个时刻的应力云图,并依据模拟碰撞过程得到的结果进行分析,得出结论.     

钢板墙-双肢C型钢框架简化模型

采用试验与有限元相结合的方法分析了钢板墙-双肢C型钢框架在低周反复荷载作用下的力学性能。在此基础上提出了一种构造简单、力学性能良好的四拉杆等效模型(FSEM)。通过FSEM模型分析了柱刚度系数、钢板墙高厚比和钢板墙高宽比,并与传统有限元模型结果进行了对比。结果表明,FSEM模型精度较高,静力计算时与传统壳单元模型的误差在10%以内,可以在设计中简化计算。提出了FSEM模型等效拉杆的倾角、截面面积计算公式,并建议该类框架钢板墙高厚比取600~1000,高宽比取0.5~1.0,柱刚度系数取79.6~99.5,为实际工程中的设计计算提供参考。     

冰载荷下不锈钢复合板挠度特性分析

以复合板中面的挠度响应作为不锈钢复合板抗冲击性能的评价指标,基于能量法和经典层合板理论,考虑层间结构参数设计,通过横向载荷下的弯曲平衡微分方程,建立冰载荷下不锈钢复合板挠度响应简化解析模型。该分析模型将整个动态响应分析过程分为冰载荷计算分析和动力学方程求解两个阶段。分析了冰载荷模型的面倾角、冲击速度和碰撞位置对冰载荷的影响,确定极端工况参数,汇总接触面的节点力数据;分析了层厚比对挠度响应的影响规律;基于LS-DYNA有限元仿真以及数值算例分析,对比挠度响应仿真结果和解析计算值,验证了本文简化解析模型的准确性,研究结果对不锈钢复合板抗冲击性能分析和评估具有一定的参考价值。