Constitutive modeling for anisotropic/asymmetric hardening behavior of magnesium alloy sheets: Application to sheet springback

The constitutive model for the unusual asymmetric hardening behavior of magnesium alloy sheet presented in a companion paper (Lee, M.G., Wagoner, R.H., Lee, J.K., Chung, K., Kim, H.Y., 2008. Constitutive modeling for anisotropic/asymmetric hardening behavior of magnesium alloy sheet, Int. J. Plasticity 24(4), 545–582) was applied to the springback prediction in sheet metal forming. The implicit finite element program ABAQUS was utilized to implement the developed constitutive equations via user material subroutine. For the verification purpose, the springback of AZ31B magnesium alloy sheet was measured using the unconstrained cylindrical bending test of Numisheet (Numisheet ’2002 Benchmark Problem, 2002. In: Yang, D.Y., Oh, S.I., Huh, H., Kim, Y.H. (Eds.), Proceedings of 5th International Conference and Workshop on Numerical Simulation of 3D Sheet Forming Processes, Jeju, Korea) and 2D draw bend test. With the specially designed draw bend test the direct restraining force and long drawn distance were attainable, thus the measurement of the springback could be made with improved accuracy comparable with conventional U channel draw bend test. Besides the developed constitutive models, other models based on isotropic constitutive equations and the Chaboche type kinematic hardening model were also considered. Comparisons were made between simulated results by the finite element analysis and corresponding experiments and the newly proposed model showed enhanced prediction capability, which was also supported by the simple bending analysis adopting asymmetric stress–strain response.     

Three-dimensional micromechanical modeling of voided polymeric materials

A three-dimensional micromechanical unit cell model for particle-filled materials is presented. The cell model is based on a Voronoi tessellation of particles arranged on a body-centered cubic (BCC) array. The three-dimensionality of the present cell model enables the study of several deformation modes, including uniaxial, plane strain and simple shear deformations, as well as arbitrary principal stress states.The unit cell model is applied to studies on the micromechanical and macromechanical behavior of rubber-toughened polycarbonate. Different load cases are examined, including plane strain deformation, simple shear deformation and principal stress states. For a constant macroscopic strain rate, the different load cases show that the macroscopic flow strength of the blend decreases with an increase in void volume fraction, as expected. The main mechanism for plastic deformation is broad shear banding across inter-particle ligaments. The distributed nature of plastic straining acts to reduce the amount of macroscopic strain softening in the blend as the initial void volume fraction is increased. In the case of plane strain deformation, the plastic flow is observed to initiate across inter-particle ligaments in the direction of constraint. This particular mode of deformation could not have been captured using a two-dimensional, plane strain idealization of cylindrical voids in a matrix.The potential for localized crazing and/or cavitation in the matrix is addressed. It is observed that the introduction of voids acts to relieve hydrostatic stress in the matrix material, compared to the homopolymer. It is also seen that the predicted peak hydrostatic stress in the matrix is higher under plane strain deformation than under triaxial tension (with equal lateral stresses), for the same macroscopic stress triaxiality.The effect of void volume fraction on the macroscopic uniaxial tension behavior of the different blends is examined using a Considère construction for dilatant materials. The natural draw ratio was predicted to decrease with an increase in void volume fraction.     

Forming limit stresses predicted by phenomenological plasticity theories with anisotropic work-hardening behavior

Forming limit stresses of sheet metals subjected to linear and combined stress paths are analyzed using the M-K model in conjunction with two anisotropic work-hardening models: a work-hardening model which is capable of describing Bauschinger and cross-hardening effects, and a work-hardening model which cannot predict the cross-hardening effect. It is found that the forming limit stress is path-independent when the stress–strain curves for the linear and combined stress paths agree well with each other. On the other hand, the forming limit stress for the combined stress path depends on the strain path when the prestrain changes the subsequent stress–strain relation. We conclude that the stress-based forming limit criterion is efficient only for a material with a work-hardening behavior that is not affected by strain path change. The influence of the work-hardening behavior on the forming limit stress is discussed in detail.     

Multiscale modeling of plasticity based on embedding the viscoplastic self-consistent formulation in implicit finite elements

This paper is concerned with the multiscale simulation of plastic deformation of metallic specimens using physically-based models that take into account their polycrystalline microstructure and the directionality of deformation mechanisms acting at single-crystal level. A polycrystal model based on self-consistent homogenization of single-crystal viscoplastic behavior is used to provide a texture-sensitive constitutive response of each material point, within a boundary problem solved with finite elements (FE) at the macroscale. The resulting constitutive behavior is that of an elasto-viscoplastic material, implemented in the implicit FE code ABAQUS. The widely-used viscoplastic selfconsistent (VPSC) formulation for polycrystal deformation has been implemented inside a user-defined material (UMAT) subroutine, providing the relationship between stress and plastic strain-rate response. Each integration point of the FE model is considered as a polycrystal with a given initial texture that evolves with deformation. The viscoplastic compliance tensor computed internally in the polycrystal model is in turn used for the minimization of a suitable-designed residual, as well as in the construction of the elasto-viscoplastic tangent stiffness matrix required by the implicit FE scheme.Uniaxial tension and simple shear of an FCC polycrystal have been used to benchmark the accuracy of the proposed implicit scheme and the correct treatment of rotations for prediction of texture evolution. In addition, two applications are presented to illustrate the potential of the multiscale strategy: a simulation of rolling of an FCC plate, in which the model predicts the development of different textures through the thickness of the plate; and the deformation under 4-point bending of textured HCP bars, in which the model captures the dimensional changes associated with different orientations of the dominant texture component with respect to the bending plane.     

Multiscale modeling of the plasticity in an aluminum single crystal

This paper describes a numerical, hierarchical multiscale modeling methodology involving two distinct bridges over three different length scales that predicts the work hardening of face centered cubic crystals in the absence of physical experiments. This methodology builds a clear bridging approach connecting nano-, micro- and meso-scales. In this methodology, molecular dynamics simulations (nanoscale) are performed to generate mobilities for dislocations. A discrete dislocations numerical tool (microscale) then uses the mobility data obtained from the molecular dynamics simulations to determine the work hardening. The second bridge occurs as the material parameters in a slip system hardening law employed in crystal plasticity models (mesoscale) are determined by the dislocation dynamics simulation results. The material parameters are computed using a correlation procedure based on both the functional form of the hardening law and the internal elastic stress/plastic shear strain fields computed from discrete dislocations. This multiscale bridging methodology was validated by using a crystal plasticity model to predict the mechanical response of an aluminum single crystal deformed under uniaxial compressive loading along the [4 2 1] direction. The computed strain-stress response agrees well with the experimental data.     

Experimental investigation and modeling of non-monotonic creep behavior in polymers

The deformation behavior of two unfilled engineering thermoplastics, ultra high molecular weight polyethylene (UHMWPE) and polycarbonate (PC), has been investigated in creep test conditions. It has been found that a loading history (prior to the creep test) comprising of loading to a maximum stress or strain value followed by partial unloading to arrive at the target stress value can greatly modify the strain-time behavior. Under such a test protocol, while the expected increase in strain during creep (constant tensile load) is observed, at relatively low creep stresses specimens have also demonstrated a monotonic decrease in strain. In an intermediate stress range, specimens have demonstrated time dependent behavior comprising of a transition from decreasing to increasing strain during creep in tension. This paper presents experimental results to delineate these findings and explore the effect of prior strain rate on the qualitative and quantitative changes in the output (strain-time) behavior. Furthermore, modification of the viscoplasticity theory based on overstress (VBO) model into a double element configuration is introduced. These changes confer upon the model the ability to yield non-monotonic behavior in creep, and supporting simulation results have been included. These changes, therefore, allow the model to simulate strain rate sensitivity, creep, relaxation, and recovery behavior, but more importantly address the issue of non-monotonic changes in creep and relaxation when a loading history involves some degree of unloading.     

Comparison of the work-hardening of metallic sheets using tensile and shear strain paths

This work deals with the characterization of the kinematic work-hardening of a bake-hardening steel. A shear test device has been designed and its use for the characterization of the work-hardening of sheet metals is described. Two main results are presented. Firstly, a local strain measurement, based on the following of three dots drawn on the gauge area, gives the evolution of the strain tensor eigenvalues during the test. It is shown, by comparing the theoretical kinematics of simple shear with a slightly perturbated one, that the strain state is close to the ideal one in the center of the gauge area. Secondly, reversal of the shear direction is performed after several prestrain and the evolution of the kinematic work-hardening with the equivalent plastic strain has been identified using an anisotropic elasto-viscoplastic model of Hill 1948 type. Isotropic and kinematic contributions of the work-hardening are also calculated from loading–unloading tensile tests and are compared to those obtained from the simple shear tests. The results show a discrepancy between both identification for the isotropic and the kinematic hardening. However, they are in agreement concerning the evolution of the global work-hardening.     

Necking in glassy polymers: Effects of intrinsic anisotropy and structural evolution kinetics in their viscoplastic flow

Two recently proposed developments of the Glass–Rubber constitutive model for glassy polymers treat the viscoplastic deformation as intrinsically anisotropic, and incorporate the kinetics of structural evolution. These features enable the model to capture better the distinctive features of glassy polymers’ constitutive response: post-yield strain-softening and strain-hardening and effects of pre-existing molecular orientation. They have been combined to form a new variant of the model, and the consequences for necking have been explored. Uniaxial extension of prismatic bars was simulated using the finite element method, employing a numerical implementation of the new model, with material parameters of polystyrene. Strain localization predicted with the new model was found to be systematically retarded as compared to predictions with the original (intrinsically isotropic) version of the model, for the same conditions. In particular, the effect of frozen-in molecular orientation was examined. This was found to retard strain localization for stretching parallel to the orientation direction, for both models. But the localization predicted with the new model was always significantly less pronounced than with the original model. Indeed, for sufficiently high pre-orientation (e.g. a uniaxial stretch of 2.2), localization could be effectively prevented with the new model, under conditions when otherwise failure by necking is predicted. Such results can all be explained in terms of a linear stability analysis. They suggest that all previous simulations of necking in glassy polymers made using intrinsically isotropic representations of polymer viscoplasticity may have over-predicted the rate of strain localization.     

Modeling the evolution of crystallographic dislocation density in crystal plasticity

Dislocations are the most important material defects in crystal plasticity, and although dislocation mechanics has long been understood as the underlying physical basis for continuum crystal plasticity formulations, explicit consideration of crystallographic dislocation mechanics has been largely absent in working constitutive models. Here, dislocation density state variables evolve from initial conditions according to equations based on fundamental concepts in dislocation mechanics such as the conservation of Burgers vector in multiplication and annihilation processes. The model is implemented to investigate the polyslip behavior of single-crystal aluminum. The results not only capture the mechanical stress/strain response, but also detail the development of underlying dislocation structure responsible for the plastic behavior.     

Advances in experiments on metal sheets and tubes in support of constitutive modeling and forming simulations

This work is a review of experimental methods for observing and modeling the anisotropic plastic behavior of metal sheets and tubes under a variety of loading paths, such as biaxial compression tests; biaxial tension tests on metal sheets and tubes using closed-loop electrohydraulic testing machines; the abrupt strain path change method for detecting a yield vertex and subsequent yield loci without unloading; in-plane stress reversal tests on metal sheets; and multistage tension tests. Observed material responses are compared with the predictions of phenomenological plasticity models. Special attention is paid to the plastic deformation behavior of materials commonly used in industry, and to verifying the validity of conventional anisotropic yield criteria for those materials and associated flow rules at large plastic strains. The effects of using appropriate anisotropic yield criteria on the accuracy of simulations of forming defects, such as large springback and fracture, are also presented to highlight the importance of accurate material testing and modeling.     

Disorder,pre-stress and non-affinity in polymer 8-chain models

To assess the role of single-chain elasticity, non-affine strain fields and pre-stressed reference states we present and discuss the results of numerical and analytical analyses of a modified 8-chain Arruda–Boyce model for cross-linked polymer networks. This class of models has proved highly successful in modeling the finite-strain response of flexible rubbers. We extend it to include the effects of spatial disorder and the associated non-affinity, and use it to assess the validity of replacing the constituent chain's nonlinear elastic response with equivalent linear, Hookean springs. Surprisingly, we find that even in the regime of linear response, the full polymer model gives very different results from its linearized counterpart, even though none of the chains are stretched beyond their linear regime. We demonstrate that this effect is due to the fact that the polymer models are under considerable pre-stress in their ground state. We show that pre-stress strongly suppresses non-affinity in these unit cell models, resulting in a marked stiffening of the bulk response. Polymer networks with some degree of flexibility are thus intrinsically prestressed, and one effect of such prestresses is to reduce non-affine deformations. Combined, these findings may help explain why fully affine mechanical models, in many cases, predict the bulk mechanical response of disordered polymer networks so well.     

A finite-deformation-based phenomenological theory for shape-memory alloys

In this work we develop a finite-deformation-based, thermo-mechanically-coupled and non-local phenomenological theory for polycrystalline shape-memory alloys (SMAs) capable of undergoing austenite ↔$\leftrightarrow$ martensite phase transformations. The constitutive model is developed in the isotropic plasticity setting using standard balance laws, thermodynamic laws and the theory of micro-force balance (Fried and Gurtin, 1994). The constitutive model is then implemented in the ABAQUS/Explicit (2009) finite-element program by writing a user-material subroutine. Material parameters in the constitutive model were fitted to a set of superelastic experiments conducted by Thamburaja and Anand (2001) on a polycrystalline rod Ti–Ni. With the material parameters calibrated, we show that the experimental stress-biased strain–temperature-cycling and shape-memory effect responses are qualitatively well-reproduced by the constitutive model and the numerical simulations. We also show the capability of our constitutive mode in studying the response of SMAs undergoing coupled thermo-mechanical loading and also multi-axial loading conditions by studying the deformation behavior of a stent unit cell.     

Nonlinear constitutive models from nanoindentation tests using artificial neural networks

This paper presents a new approach using Artificial Neural Networks (ANNs) models to simulate the response during nanohardness tests of a variety of materials with nonlinear behavior. The ANNs continuous input and output variables usually include material parameters, indentation deflection, and resisting force. Different ANN models, including dimensionless input/output variables, are generated and trained with discrete finite-element (FE) simulations with different geometries and nonlinear material parameters. Only the monotonic loading part of the load–displacement indentation response is used to generate the trained ANN models. This is a departure from classical indentation simulations or tests where typically the unloading portion is used to determine the stiffness and hardness. The experimental part of this study includes nanoindentation tests performed on a silicon (Si) substrate with and without a nanocrystalline copper (Cu) film. The new ANN models are used to back-calculate (inverse problem) the in situ nonlinear material parameters for different copper material systems. The results are compared with available data in the literature. The proposed FE–ANN modeling approach is very effective and can be used in calibrating and predicting the in situ inelastic material properties using the monotonic part of the indentation response and for depths above 50 nm where the overall resisting force represents a continuum response.     

A finite element formulation based on non-associated plasticity for sheet metal forming

In the present paper, a finite element formulation based on non-associated plasticity is developed. In the constitutive formulation, isotropic hardening is assumed and an evolution equation for the hardening parameter consistent with the principle of plastic work equivalence is introduced. The yield function and plastic potential function are considered as two different functions with functional form as the yield function of Hill [Hill, R., 1948. Theory of yielding and plastic flow of anisotropic metals. Proc. Roy. Soc. A 193, 281–297] or Karafillis–Boyce associated model [Karafillis, A.P. Boyce, M., 1993. A general anisotropic yield criterion using bounds and a transformation weighting tensor. J. Mech. Phys. Solids 41, 1859–1886]. Algorithmic formulations of constitutive models that utilize associated or non-associated flow rule coupled with Hill or Karafillis–Boyce stress functions are derived by application of implicit return mapping procedure. Capabilities in predicting planar anisotropy of the Hill and Karafillis–Boyce stress functions are investigated considering material data of Al2008-T4 and Al2090-T3 sheet samples. The accuracy of the derived stress integration procedures is investigated by calculating iso-error maps.     

Visco-plastic constitutive modeling on Ohno-Wang kinematic hardening rule for uniaxial ratcheting behavior of Z2CND18.12N steel

Experimental results of monotonic uniaxial tensile tests at different strain rates and the reversed strain cycling test showed the characteristics of rate-dependence and cyclic hardening of Z2CND18.12N austenitic stainless steel at room temperature, respectively. Based on the Ohno-Wang kinematic hardening rule, a visco-plastic constitutive model incorporated with isotropic hardening was developed to describe the uniaxial ratcheting behavior of Z2CND18.12N steel under various stress-controlled loading conditions. Predicted results of the developed model agreed better with experimental results when the ratcheting strain level became higher, but the developed model overestimated the ratcheting deformation in other cases. A modified model was proposed to improve the prediction accuracy. In the modified model, the parameter m_i of the Ohno-Wang kinematic hardening rule was developed to evolve with the accumulated plastic strain. Simulation results of the modified model proved much better agreement with experiments.     

Three dimensional combined fracture–plastic material model for concrete

This paper describes a combined fracture–plastic model for concrete. Tension is handled by a fracture model, based on the classical orthotropic smeared crack formulation and the crack band approach. It employs the Rankine failure criterion, exponential softening, and it can be used as a rotated or a fixed crack model. The plasticity model for concrete in compression is based on the Menétrey–Willam failure surface, the plastic volumetric strain as a hardening/softening parameter and a non-associated flow rule based on a nonlinear plastic potential function. Both models use a return-mapping algorithm for the integration of constitutive equations. Special attention is given to the development of an algorithm for the combination of the two models. The suggested combination algorithm is based on a recursive substitution, and it allows for the two models to be developed and formulated separately. The algorithm can handle cases when failure surfaces of both models are active, but also when physical changes such as crack closure occur. The model can be used to simulate concrete cracking, crushing under high confinement and crack closure due to crushing in other material directions. The model is integrated in a general finite element package ATENA and its performance is evaluated by comparisons with various experimental results from the literature.