Modification of the Gurson Model for shear failure

Recent experimental evidence points to limitations in characterizing the critical strain in ductile fracture solely on the basis of stress triaxiality. A second measure of stress state, such as the Lode parameter, is required to discriminate between axisymmetric and shear-dominated stress states. This is brought into the sharpest relief by the fact that many structural metals have a fracture strain in shear, at zero stress triaxiality, that can be well below fracture strains under axisymmetric stressing at significantly higher triaxiality. Moreover, recent theoretical studies of void growth reveal that triaxiality alone is insufficient to characterize important growth and coalescence features. As currently formulated, the Gurson Model of metal plasticity predicts no damage change with strain under zero mean stress, except when voids are nucleated. Consequently, the model excludes shear softening due to void distortion and inter-void linking. As it stands, the model effectively excludes the possibility of shear localization and fracture under conditions of low triaxiality if void nucleation is not invoked. In this paper, an extension of the Gurson model is proposed that incorporates damage growth under low triaxiality straining for shear-dominated states. The extension retains the isotropy of the original Gurson Model by making use of the third invariant of stress to distinguish shear dominated states. The importance of the extension is illustrated by a study of shear localization over the complete range of applied stress states, clarifying recently reported experimental trends. The extension opens the possibility for computational fracture approaches based on the Gurson Model to be extended to shear-dominated failures such as projectile penetration and shear-off phenomena under impulsive loadings.     

The modified Gurson model accounting for the void size effect

The Gurson model [J. Engrg. Mater. Technol. 99 (1977) 2] has been widely used to study the deformation and failure of metallic materials containing microvoids. The void volume fraction is the only parameter representing voids since the void size does not come into play in the Gurson model. Based on the Taylor dislocation model [Proc. R. Soc. (Lond.) A145 (1934) 362; J. Int. Metals 62 (1938) 307], we extend the Gurson model to account for the void size effect. It is shown that the yield surfaces for micron- and submicron-sized voids are significantly larger than that given by the Gurson model. For a voided, dilating material subject to uniaxial tension, the void size has essentially no effect on the stress–strain curve at small initial void volume fraction. However, as the initial void volume fraction increases, the void size effect may become significant.     

Relations between a micro-mechanical model and a damage model for ductile failure in shear

Gurson type constitutive models that account for void growth to coalescence are not able to describe ductile fracture in simple shear, where there is no hydrostatic tension in the material. But recent micro-mechanical studies have shown that in shear the voids are flattened out to micro-cracks, which rotate and elongate until interaction with neighbouring micro-cracks gives coalescence. Thus, the failure mechanism is very different from that under tensile loading. Also, the Gurson model has recently been extended to describe failure in shear, by adding a damage term to the expression for the growth of the void volume fraction, and it has been shown that this extended model can represent experimental observations. Here, numerical studies are carried out to compare predictions of the shear-extended Gurson model with the shear failures predicted by the micro-mechanical cell model. Both models show a strong dependence on the level of hydrostatic tension. Even though the reason for this pressure dependence is different in the two models, as the shear-extended Gurson model does not describe voids flattening out and the associated failure mechanism by micro-cracks interacting with neighbouring micro-cracks, it is shown that the trends of the predictions are in good agreement.     

On the importance of thermo-elastic cooling in the fracture of glassy polymers at high rates

In a previous thermo-mechanical analysis [Estevez, R., Basu, S., van der Giessen, E., 2005. Analysis of temperature effects near mode I cracks in glassy polymers. Int. J. Fract. 132, 249–273] in which shear yielding of the bulk and failure by crazing were accounted for, we examined which of these two viscoplastic processes contributed to heat in mode I fracture. The present study completes this work by investigating the conditions for thermo-elastic cooling prior to crack propagation as reported experimentally by Rittel [Rittel, D., 1998. Experimental investigation of transient thermo-elastic effects in dynamic fracture. Int. J. Solids Struct. 35, 2959–2973] and Bougaut and Rittel [Bougaut, O., Rittel, D., 2001. On crack tip cooling during dynamic crack propagation. Int. J. Solids Struct. 38, 2517–2532] on high strain rate loading of PMMA. To this end, coupled thermo-mechanical finite element simulations are carried out by accounting for the thermo-elastic source, in addition to the heat sources related to shear yielding and crazing. The bulk as well as cohesive zone parameters for crazing realistically describe PMMA as they are obtained from detailed calibration experiments. Our results show that if significant thermo-elastic cooling has to be observed in the vicinity of the crack tip of a polymeric material, suppression of shear yielding as well as suppression of crazing is necessary. It seems that at these high strain rates a brittle fracture mechanism activated at very high stresses takes over from crazing, or at least that craze initiation occurs for stress levels very different to those for quasi-static conditions.     

Tension–torsion fracture experiments – Part II: Simulations with the extended Gurson model and a ductile fracture criterion based on plastic strain

An extension of the Gurson model that incorporates damage development in shear is used to simulate the tension–torsion test fracture data presented in Faleskog and Barsoum (2013) (Part I) for two steels, Weldox 420 and 960. Two parameters characterize damage in the constitutive model: the effective void volume fraction and a shear damage coefficient. For each of the steels, the initial effective void volume fraction is calibrated against data for fracture of notched round tensile bars and the shear damage coefficient is calibrated against fracture in shear. The calibrated constitutive model reproduces the full range of data in the tension–torsion tests thereby providing a convincing demonstration of the effectiveness of the extended Gurson model. The model reinforces the experiments by highlighting that for ductile alloys the effective plastic strain at fracture cannot be based solely on stress triaxiality. For nominally isotropic alloys, a ductile fracture criterion is proposed for engineering purposes that depends on stress triaxiality and a second stress invariant that discriminates between axisymmetric stressing and shear dominated stressing.     

金属基复合材料和强度与损伤分析

用观察计算力学的方法分析了金属基复合材料（ＭＭＣ）多重损伤与强度的关系,采用唯象的内聚力模型模拟纤维／基体界面的脱粘和采用Ｇ－Ｔ模型描述韧性基体的损伤。并用上述模型分析了长纤维增强ＭＭＣ在横向荷载作用下损伤演化的规律,讨论了不同界面性质与材料强度及损伤、破坏模式之间的关系。     

Numerical solution of polarization saturation/dielectric breakdown model in 2D finite piezoelectric media

The polarization saturation (PS) model [Gao, H., Barnett, D.M., 1996. An invariance property of local energy release rates in a strip saturation model of piezoelectric fracture. Int. J. Fract. 79, R25–R29; Gao, H., Zhang, T.Y., Tong, P., 1997. Local and global energy release rates for an electrically yielded crack in a piezoelectric ceramic. J. Mech. Phys. Solids 45, 491–510], and the dielectric breakdown (DB) model [Zhang, T.Y., Zhao, M.H., Cao, C.F., 2005. The strip dielectric breakdown model. Int. J. Fract. 132, 311–327] explain very well some experimental observations of fracture of piezoelectric ceramics. In this paper, the nonlinear hybrid extended displacement discontinuity-fundamental solution method (NLHEDD-FSM) is presented for numerical analysis of both the PS and DB models of two-dimensional (2D) finite piezoelectric media under impermeable and semi-permeable electric boundary conditions. In this NLHEDD-FSM, the solution is expressed approximately by a linear combination of fundamental solutions of the governing equations, which includes the extended point force fundamental solutions with sources placed at chosen points outside the domain of the problem under consideration, and the extended Crouch fundamental solutions with extended displacement discontinuities placed on the crack and the electric yielding zone. The coefficients of the fundamental solutions are determined by letting the approximated solution satisfy certain conditions on the boundary of the domain, on the crack face and the electric yielding zone. The zero electric displacement intensity factor in the PS model or the zero electric field strength intensity factor in the DB model at the outer tips of the electric yielding zone is used as a supplementary condition to determine the size of the electric yielding zone. Iteration approaches are adopted in the NLHEDD-FSM. The electric yielding zone is determined, and the extended intensity factors and the local J-integral are calculated for center cracks in piezoelectric strips. The effects of finite domain size, saturation property and different electric boundary conditions, as well as different models on the electric yielding zone and the local J-integral, are studied.     

不同应力三维度条件下孔洞的演变及修正的Gurson模型

本文对含不同形状孔洞的幂硬化材料的圆柱体胞模型，运用控制宏观应力三维工的方法进行了有限元分析。计算结果表明：１．孔洞初始形状，应力三维度对孔洞的长大有重要影响；２．Ｇｕｓｏｎ模型对孔洞长大规律的描述是不准确的，不准确度与孔洞初始形状，应力三维度有关，修正后的Ｇｕｒｓｏｎ模型与有限元结果吻合较好；３．在低应力三维度区，孔洞以及形状改变为主，在高应力三维度区，孔洞以扩张为主；     

Modeling of plane strain ductile rupture

The formation of slanted fracture under plane strain conditions is studied using the finite Element (FE) method. Constitutive models proposed by Rousselier and by Gurson are used. Rice's condition for localization is checked at every point of the FE mesh for each time step. The role of mesh design (element size, element aspect ratio, symmetry) is first studied. The different constitutive models are then compared. It is in particular shown that the use of the f function in the Gurson model favors flat fracture.     

Modeling of ductile fracture: Application of the mechanism-based concepts

This paper summarizes our recent studies on modeling ductile fracture in structural materials using the mechanism-based concepts. We describe two numerical approaches to model the material failure process by void growth and coalescence. In the first approach, voids are considered explicitly and modeled using refined finite elements. In order to predict crack initiation and propagation, a void coalescence criterion is established by conducting a series of systematic finite element analyses of the void-containing, representative material volume (RMV) subjected to different macroscopic stress states and expressed as a function of the stress triaxiality ratio and the Lode angle. The discrete void approach provides a straightforward way for studying the effects of microstructure on fracture toughness. In the second approach, the void-containing material is considered as a homogenized continuum governed by porous plasticity models. This makes it possible to simulate large amount of crack extension because only one element is needed for a representative material volume. As an example, a numerical approach is proposed to predict ductile crack growth in thin panels of a 2024-T3 aluminum alloy, where a modified Gologanu–Leblond–Devaux model [Gologanu, M., Leblond, J.B., Devaux, J., 1993. Approximate models for ductile metals containing nonspherical voids – Case of axisymmetric prolate ellipsoidal cavities. J. Mech. Phys. Solids 41, 1723–1754; Gologanu, M., Leblond, J.B., Devaux, J., 1994. Approximate models for ductile metals containing nonspherical voids – Case of axisymmetric oblate ellipsoidal cavities. J. Eng. Mater. Tech. 116, 290–297; Gologanu, M., Leblond, J.B., Perrin, G., Devaux, J., 1995. Recent extensions of Gurson’s model for porous ductile metals. In: Suquet, P. (Ed.) Continuum Micromechanics. Springer-Verlag, pp. 61–130] is used to describe the evolution of void shape and void volume fraction and the associated material softening, and the material failure criterion is calibrated using experimental data. The calibrated computational model successfully predicts crack extension in various fracture specimens, including the compact tension specimen, middle crack tension specimens, multi-site damage specimens and the pressurized cylindrical shell specimen.     

Predicting ductile fracture of low carbon steel sheets: Stress-based versus mixed stress/strain-based Mohr–Coulomb model

Two distinct implementations of the Mohr–Coulomb failure model are used in conjunction with a non-associated quadratic plasticity model to describe the onset of fracture in low carbon steel sheets. The stress-based version corresponds to the original Mohr–Coulomb model in stress space. For the mixed stress/strain-based version, the Mohr–Coulomb failure criterion is first transformed into the space of stress triaxiality, Lode angle parameter and equivalent plastic strain and then used as stress-state dependent weighting function in a damage indicator model. Basic fracture experiments including tensile specimens of different notch radii and a punch test are performed to calibrate the material parameters of the respective models. Subsequently, the models are used to predict the crack initiation in a Hasek test and during the stamping of an anticlastic structure. Unlike for the calibration experiments, the loading history during stamping is highly non-linear. Both models can be calibrated with similar accuracy, but the strain-based model predicts the instant of onset of fracture with greater accuracy in the stamping experiment which is an advantage of the empirical damage accumulation rule.     

Ductile damage evolution under triaxial state of stress: theory and experiments

In this paper, the continuum damage mechanics (CDM) model formulation proposed by [Eng. Fract. Mech. 58(1/2) (1997) 11] has been validated against ductile damage evolution experimentally measured in A533B low alloy steel under various stress triaxiality conditions. A procedure to identify the model parameters has been defined first. Then, the model has been used to simulate, via finite element analysis (FEA), tests on notched flat rectangular bars with different notch radii. The experiments and the FEA predictions are finally compared with each other. The results presented here confirm the transferability of damage parameters definition and the potential of the proposed damage model in predicting ductile failure occurrence in structures and components under multi-axial state of stress loading conditions.     

The Chaboche hardening rule: A re-evaluation of calibration procedures and a modified rule with an evolving material parameter

This study first re-examines key existing calibration procedures for the Chaboche decomposed nonlinear kinematic hardening rule. Special attention has been paid to the extent to which the predictions of calibrated models represent the physics of phenomena observed in strain- and stress-controlled cyclic tests. It has been shown and discussed that newer methods suffer from some weaknesses and may yield nonphysical results. Second, with the aim of improving the accuracy of its ratcheting strain predictions in unsymmetric stress-controlled tests, a modified calibration procedure and a new Chaboche hardening rule with an evolving material parameter is introduced. The former improves the accuracy of predicted ratcheting strains at the initial cycles, while the latter is responsible for the better agreement of the results at the higher cycles. The new model assumes there exists a linear relationship between one of the coefficient of the model and its corresponding effective/equivalent backstress. Finally, the predictions of the new model and those of the original Chaboche rule are compared with the available experimental results from the literature. It has been shown that, regardless of the level of mean stress of unsymmetric stress-controlled test, the ratcheting rates of the higher cycles are satisfactorily predicted by the proposed modified model.     

Ductile fracture of materials with high void volumefraction

In the present paper, axisymmetric cell models containing one or two voids and athree-dimensional cell model containing two voids have been used to investigate void size andspacing effect on the ductile fracture in materials with high initial void volume fraction. They areperformed for round smooth and round notched specimens under uniaxial tension. The examplematerial used for comparison is a nodular cast iron material GGG-40 with initial void volumefraction of 7.7%. The parameters considered in this paper are void size and shape foraxisymmetric cell models containing a single void, and void distribution pattern foraxisymmetric and 3D cell models containing two voids of different sizes. The results obtainedfrom these cell models by using FEM calculations are compared with the Gurson model, theGurson–Tvergaard–Needleman model, the Rice–Tracey model and the modified Rice–Traceymodel. It can be stated that the influence of void size and void spacing on the growth in volumeof voids is very large, and it is dependent on the distribution of voids. Using non-uniform voiddistribution, the results of axisymmetric cell models can explain how a void can grow in anunstable state under very low stress triaxiality at very small strain as observed in experiments.Calculations using cell models containing two voids give very different results about the stableand unstable growth of voids which are strongly dependent on the configuration of cell model.     

A micromechanical explanation of the mean stress effect in high cycle fatigue

A micro–macro approach of multiaxial fatigue in unlimited endurance is presented in this study, as an extension of a previous model recently proposed by the authors [Monchiet, V., Charkaluk, E., Kondo, D., 2006. A plasticity–damage based micromechanical modelling in high cycle fatigue. C.R. Mécanique 334 (2), 129–136]. It allows to take into account coupling between polycrystalline plasticity and damage mechanisms which occur at the scale of persistent slip bands (PSB) during cyclic deformation. The plasticity–damage coupled model is obtained by adapting the Gurson [Gurson, A.L., 1977. Continuum theory of ductile rupture by void nucleation and growth: part I – yield criteria and flow rules for porous ductile media. J. Eng. Mater. Technol. 99, 2–15] limit analysis to polycrystalline materials to take into account microvoids growth along PSBs. The macroscopic fatigue criterion corresponds to microcracks nucleation at the PSB–matrix interface. It is shown that this criterion accounts for the effect of the mean stress and of the hydrostatic pressure in high cycle fatigue. Such features of HCF are related to the damage micro-mechanisms. Finally, some illustrations concerning the particular case of cyclic affine loadings are presented and comparisons of the predictions of the fatigue criterion with experimental data show the relevance of this new approach.     

RVE-based studies on the coupled effects of void size and void shape on yield behavior and void growth at micron scales

The present paper extends the Gurson and GLD models [Gurson, A.L., 1977. Continuum theory of ductile rupture by void nucleation and growth, Part I—yield criteria and flow rules for porous ductile media. J. Mech. Phys. Solids 99, 2–15; Gologanu, M., Leblond, J.B., Devaux, J., 1993. Approximate models for ductile metals containing non-spherical voids—case of axisymmetric prolate ellipsoidal cavities. J. Mech. Phys. Solids 41, 1723–1754; Gologanu, M., Leblond, J.B., Devaux, J., 1994. Approximate models for ductile metals containing non-spherical voids—case of axisymmetric oblate ellipsoidal cavities. J. Eng. Mater. Technol. 116, 290–297] to involve the coupled effects of void size and void shape on the macroscopic yield behavior of non-linear porous materials and on the void growth. A spheroidal representative volume element (RVE) under a remote axisymmetric homogenous strain boundary condition is carefully analyzed. A wide range of void aspect ratios covering the oblate spheroidal, spherical and prolate spheroidal void are taken into account to reflect the shape effect. The size effect is captured by the Fleck–Hutchinson phenomenological strain gradient plasticity theory [Fleck, N.A., Hutchinson, J.W., 1997. Strain gradient plasticity. In: Hutchinson, J.W., Wu, T.Y. (Eds.), Advance in Applied Mechanics, vol. 33, Academic Press, New York, pp. 295–361]. A new size-dependent damage model like the Gurson and GLD models is developed based on the traditional minimum plasticity potential principle. Consequently, the coupled effects of void size and void shape on yield behavior of porous materials and void growth are discussed in detail. The results indicate that the void shape effect on the yield behavior of porous materials and on the void growth can be modified dramatically by the void size effect and vice versa. The applied stress triaxiality plays an important role in these coupled effects. Moreover, there exists a cut-off void radius r_c, which depends only on the intrinsic length l₁ associated with the stretch strain gradient. Voids of effective radius smaller than the critical radius r_c are less susceptible to grow. These findings are helpful to our further understanding to some impenetrable micrographs of the ductile fracture surfaces.     

A heuristic approach to microcracking and fracture for ceramics with statistical consideration

Microcracking damage and toughening are examined for ceramics. These effects have been found to depend on the material microstructure and macrocrack growth. Isotropic damage, attributed to random distribution of microcrack location, length and orientation can be associated with a disordered microstructure and a non-uniform residual stress field. When the applied stress is the main cause of cracking, the microcrack distribution is no longer random such as a system of quasi-parallel cracks. To highlight the effect of crack interaction, discrete models are advanced where damage is simulated by a distribution of microcracks. The dilute concentration assumption is invoked to simplify the analysis.The two-dimensional discrete model is based on a phenomenological approach that is statistical in character. Interactions of microcracks and with a macrocrack are considered by means of a boundary element technique (A. Brencich, A. Carpinteri, Int. J. Fracture 76 (1996) 373–389; A. Brencich, A. Carpinteri, Eng. Fract. Mech. 59 (1998) 797–814) where both isotropic and anisotropic damage could be treated. Comparisons with other results are made to show that the model can be applied to analyse the fracture behaviour of different materials.     

Anisotropy Invariant Reynolds Stress Model of Turbulence (AIRSM) and its Application to Attached and Separated Wall-Bounded Flows

Numerical predictions with a differential Reynolds stress closure, which in its original formulation explicitly takes into account possible states of turbulence on the anisotropy-invariant map, are presented. Thus the influence of anisotropy of turbulence on the modeled terms in the governing equations for the Reynolds stresses is accounted for directly. The anisotropy invariant Reynolds stress model (AIRSM) is implemented and validated in different finite-volume codes. The standard wall-function approach is employed as initial step in order to predict simple and complex wall-bounded flows undergoing large separation. Despite the use of simple wall functions, the model performed satisfactory in predicting these flows. The predictions of the AIRSM were also compared with existing Reynolds stress models and it was found that the present model results in improved convergence compared with other models. Numerical issues involved in the implementation and application of the model are also addressed.     

Numerical failure analysis of a stretch-bending test on dual-phase steel sheets using a phenomenological fracture model

Advanced High Strength Steels (AHSS) are increasingly used in automotive industry due to their superior strength and substantial weight advantage. However, their compromised ductility gives rise to numerous manufacturing issues. One of them is the so-called ‘shear fracture’ often observed on tight radii during stamping processes. Since traditional approaches, such as the Forming Limit Diagram (FLD), are unable to predict this type of fractures, great efforts have been made to develop failure criteria that could predict shear fractures. In this paper, a recently developed Modified Mohr–Coulomb (MMC) ductile fracture criterion (Bai and Wierzbicki, 2010) is adopted to analyze the failure behavior of a Dual Phase (DP) steel sheet during stretch-bending operations. The plasticity and ductile fracture of the present sheet are fully characterized by a Hill’48 orthotropic model and a MMC fracture model, respectively. Finite element models with three different element types (3D, shell and plane strain) were built for a Stretch Forming Simulator (SFS) test (Shih and Shi, 2008), numerical simulations with four different R/t values (die radius normalized by sheet thickness) were performed. It has been shown that the 3D and shell element simulations can predict failure location/mode, the upper die load–displacement responses as well as wall stress and wrap angle at the onset of fracture for all R/t values with good accuracy. Furthermore, a series of parametric studies were conducted on the 3D element model, and the effect of tension level (clamping distance), tooling friction, mesh size and fracture locus on failure modes and load–displacement responses were investigated.