Computational Homogenisation of Polycrystalline Elastoplastic Microstructures at Finite Deformation

During sheet bulk metal forming processes both, flat geometries and three-dimensional structures change their shape significantly while undergoing large plastic deformations. As for forming processes, FE-simulations are often done before in situ experiments, a very accurate material model is required, performing well for a huge variety of different geometrical characteristics. Because of the crystalline nature of metals, anisotropies have to be taken into account. Macroscopically observable plastic deformation is traced back to dislocations within considered slip systems in the crystals causing plastic anisotropy on the microscopic and the macroscopic level. A finite crystal plasticity model is used to model the behaviour of polycrystalline materials in representative volume elements (RVEs) of the microstructure. A multiplicative decomposition of the deformation gradient into elastic and plastic parts is performed, as well as a volumetric-deviatoric split of the elastic contribution. In order to circumvent singularities stemming from the linear dependency of the slip system vectors, a viscoplastic power-law is introduced providing the evolution of the plastic slips and slip resistances. The model is validated with experimental microstructural data under deformation. Through homogenisation and optimisation techniques, effective stress-strain curves are determined and can be compared to results from real forming processes leading to a suitable effective material model. (© 2011 Wiley-VCH Verlag GmbH & Co. KGaA, Weinheim)     

Simulation of micro-cutting considering finite deformation crystal plasticity

Micro-machining processes on metalic microstructures are influenced by the crystal structure, i. e. the grain orientation. Furthermore, the chip formation underlies large deformations. To perform finite element simulations of micro-cutting processes, a large deformation material model is necessary in order to model the hyperelastic and finite plastic material behaviour. In the case of cp-titanium material with hcp-crystal structure the anisotropic behaviour must be considered by an appropriate set of slip planes and slip directions. In the present work the impact of the grain orientation on the plastic deformation is demonstrated by means of finite element simulations of a finite deformation single slip crystal plasticity model. (© 2016 Wiley-VCH Verlag GmbH & Co. KGaA, Weinheim)     

Variational Phase Field Modeling of Laminate Deformation Microstructure in Finite Gradient Crystal Plasticity

The macroscopic mechanical behavior of many materials crucially depends on the formation and evolution of their microstructure. In this work, we consider the formation and evolution of laminate deformation microstructure in plasticity. Inspired by work on the variational modeling of phase transformation [5] and building on related work on multislip gradient crystal plasticity [9], we present a new finite strain model for the formation and evolution of laminate deformation microstructure in double slip gradient crystal plasticity. Basic ingredients of our model are a nonconvex hardening potential and two gradient terms accounting for geometrically necessary dislocations (GNDs) by use of the dislocation density tensor and regularizing the sharp interfaces between different kinematically coherent plastic slip states. The plastic evolution is described by means of a nonsmooth dissipation potential for which we propose a new regularization. We formulate a continuous gradient-extended rate-variational framework and discretize it in time to obtain an incremental-variational formulation. Discretization in space yields a finite element formulation which is used to demonstrate the capability of our model to predict the formation and evolution of laminate deformation microstructure in f.c.c. Copper with two active slip systems in the same slip plane. (© 2012 Wiley-VCH Verlag GmbH & Co. KGaA, Weinheim)     

Modelling Metals At Finite Deformation

During metal forming processes, substantial microstructural changes occur in the material due to large plastic deformations leading to different mechanical properties. It is of great interest to predict the behaviour of these materials at different fabriction stages and of the final product. At first glance, the behaviour of metals can be approached by an elastoplastic isotropic material model with a volumetric-deviatoric split and isotropic hardening. In order to perform the calculations, a logarithmic strain is considered in the principal directions of stress and strain space, allowing to make predictions even at finite deformations. Because of the actual nature of metals, the crystalline structure, the deformation at the microstructural level is much more complex. Due to the mathematically algorithmic form of an elastic predictor and a plastic corrector, the elastoplastic model can be extended to crystal plasticity which is similarly handled in terms of a critical resolved shear stress on defined slip planes in the crystal. Hardening can be modelled through a viscoplastic power law. (© 2010 Wiley-VCH Verlag GmbH & Co. KGaA, Weinheim)     

Configurational Forces in Crystal Plasticity

The surface morphology of micro machined surfaces depends on the heterogeneous microstructure. A crystal plasticity model is used to describe the plastic deformation in cp-titanium with its hcp crystal structure. Therefore the basal and prismatic slip systems are taken into account. Furthermore, self and latent hardening are considered. The rate dependency is motivated by a visco plastic evolution law. The cutting process of cp-titanium is modeled within the concept of configurational forces for a standard dissipative media. This framework is implemented into the finite element method. An example illustrates the effects of the microstructure on plastic deformation and configurational forces. (© 2013 Wiley-VCH Verlag GmbH & Co. KGaA, Weinheim)     

From Dislocation Motion to an Additive Velocity Gradient Decomposition, and Some Simple Models of Dislocation Dynamics

A mathematical theory of time-dependent dislocation mechanics of unrestricted geometric and material nonlinearity is reviewed. Within a ``small deformation" setting, a suite of simplified and interesting models consisting of a nonlocal Ginzburg Landau equation, a nonlocal level set equation, and a nonlocal generalized Burgers equation is derived. In the finite deformation setting, it is shown that an additive decomposition of the total velocity gradient into elastic and plastic parts emerges naturally from a micromechanical starting point that involves no notion of plastic deformation but only the elastic distortion, material velocity, dislocation density and the dislocation velocity. Moreover, a plastic spin tensor emerges naturally as well.     

Elastoplastic torsion of a cylindrical rod for finite deformations

A solution of the problem of the torsion of a cylindrical rod was obtained in /1/ for a general, isotropic, incompressible elastic material. The present paper gives an analytical solution of the elastoplastic torsion problem for finite deformations, written in terms of quadratures of elliptic functions. The non-linear kinematics of elastoplastic deformation is introduced into the defining equations with the help of a multiplicative decomposition of the deformation gradient into elastic and plastic components /2, 3/. The elastic deformation and rate of plastic deformation are related to the state of stress of the body, in accordance with the defining Mooney-Rivlin equations /4/ and the law of flow for finite deformations associated with the Tresca yield condition /5/. A non-linear first-order partial differential equation and the initial data at the elastoplastic boundary are obtained in order to determine the angle of rotation within the plastic zone of the basis formed from the eigenvectors of the stress tensor, relative to the radial direction. The integration of the resulting equation is reduced to determining the general integral of the Ricatti equation with right-hand side determined from the angular velocity of flow of the material within the plastic zone. It is shown that neglecting the finiteness of the deformation leads to too high an estimate of the rigidity of the rod.     

A Phase Field Approach for Martensitic Transformations and Crystal Plasticity

This work is motivated by cryogenic turning which allows end shape machining and simultaneously attaining a hardened surface due to deformation induced martensitic transformations. To study the process on the microscale, a multivariant phase field model for martensitic transformations in conjunction with a crystal plastic material model is introduced. The evolution of microstructure is assumed to follow a time-dependent Ginzburg-Landau equation. To solve the field equations the finite element method is used. Time integration is performed with Euler backward schemes, on the global level for the evolution equation of the phase field, and on the element level for the crystal plastic material law. (© 2014 Wiley-VCH Verlag GmbH & Co. KGaA, Weinheim)     

Comparison of dilatant plasticity models in application to rubber-toughened polymers

The overall deformation behavior of rubber-toughened polymers (e.g. PC/ABS blends) exhibits a pronounced plastic dilatancy. As this volume increase results from diverse micromechanisms the appropriate structure of a macroscopic model is not obvious. In this contribution, different material models featuring plastic dilatancy are compared with regard to their ability to capture the deformation behavior of PC/ABS in different loading situations. All models are calibrated to match experimental data under uniaxial tension in terms of true stress-strain curves and the evolution of volume strain. Afterwards they are employed in finite element (FE) simulations of single-edge-notch-tensile (SENT) tests. Patterns of plastic deformation computed from the different material models are compared to experimental findings. (© 2016 Wiley-VCH Verlag GmbH & Co. KGaA, Weinheim)     

On physics-based crystal plasticity models: Application to virtual material testing of sheet metals

It is possible to pursue a multi-scale modeling approach for sheet forming simulations by applying the concept of virtual material testing to determine the yield surface from the microstructure of a given material. Full-field simulations with phenomenological crystal plasticity models are widely used for this kind of investigations. However, recent developments focus on incorporating physical quantities like dislocation density into these models. In this work, a dislocation density based crystal plasticity model is used to investigate the plastic anisotropy of the deep drawing steel DC04. In particular, we focus on the prediction of R-values, which can be used to calibrate macroscopic plasticity models. (© 2014 Wiley-VCH Verlag GmbH & Co. KGaA, Weinheim)     

Simulation of micro cutting considering crystal plastic deformations

The micro cutting process of microstructured material is simulated with consideration of the heterogeneities of the microstructure. In the case of cp-titanium with its hcp crystal structure the basal and prismatic slip systems are taken into account. The concept of crystal plasticity for large deformations is applied considering elastic anisotropy, self and latent hardening. The visco-plastic evolution law incorporates rate dependent material behavior. This setup is implemented within the finite element method. The effects of the microstructure are demonstrated by an illustrative example and a comparison to an isotropic von Mises elasto-plastic material. (© 2015 Wiley-VCH Verlag GmbH & Co. KGaA, Weinheim)     

Distribution of dislocation density and residual stresses in plastically deformed specimens: numerical studies

A two-scale approach to the simulation of mechanical properties of metallic materials is considered. On the macroscopic level, the material behavior is described by a phenomenological model of finite strain viscoplasticity with nonlinear kinematic hardening. In particular, the process-induced plastic anisotropy is captured by backstresses. On the microstructural level, the so called “load path sensitive two-population dislocation cell model” is implemented. It describes an evolving dislocation cell structure with dislocation populations for dislocation cell walls and the cell interior. Owing to the coupling with the phenomenological plasticity model, it can describe the evolution of the dislocation densities depending on the load path. The applicability of the multiscale approach to the FEM simulation of severe plastic deformation processes such as Equal Channel Angular Pressing is demonstrated. (© 2014 Wiley-VCH Verlag GmbH & Co. KGaA, Weinheim)     

Parameter–identification of macroscopic material models based on virtual testing of given material mesostructures

For many heterogeneous materials such as composites and polycrystals, the material modeling for the constituents on a representative mesoscale can be considered as known, including concrete values of their inherent material parameters. Typical examples are isotropic elastic–plastic models for the constituents of composites or anisotropic crystal–plasticity models for the grains of polycrystals. This knowledge can be exploited with regard to the modeling of the homogenized macroscopic response. In particular, parameters in macroscopic models may be identified by virtual experiments provided by a computational deformation–driving of representative mesostructures. This paper outlines the general concept for the parameter–identification of macroscopic materialmodels based on the virtual testing of given material mesostructures. The virtual test data are obtained in the form of multi–dimensional stress–strain paths by applying different deformation gradients to a given mesostructure. After specifying a corresponding macroscopic material model covering the observed effects on the macroscale, the material parameters are identified by a least–square–type optimization procedure that optimizes the macroscopic material parameters. (© 2004 WILEY‐VCH Verlag GmbH & Co. KGaA, Weinheim)     

Elastoplastic deformation during projectile–wall collision

The Smoothed Particle Hydrodynamics method for elastic solid deformation is modified to include von Mises plasticity with linear isotropic hardening and is then used to investigate high speed collisions of elastic and elastoplastic bodies. The Lagrangian mesh-free nature of SPH makes is very well suited to these extreme deformation problems eliminating issues relating to poor element quality at high strains that limits finite element usage for these types of problems. It demonstrates excellent numerical stability at very high strains (of more than 200%). SPH can naturally track history dependent material properties such as the cumulative plastic strain and the degree of work hardening produced by its strain history. The high speed collisions modelled here demonstrate that the method can cope easily with collisions of multiple bodies and can also naturally resolve self-collisions of bodies undergoing high levels of plastic strain. The nature and the extent of the elastic and plastic deformation of a rectangular body impacting on an elastic wall and of an elastic projectile impacting on a thin elastic wall are investigated. The final plastically deformed shapes of the projectile and wall are compared for a range of material properties and the evolution of the maximum plastic strain throughout each collision and the coefficient of restitution are used to make quantitative comparisons. Both the elastoplastic projectile–elastic wall and the elastic projectile–elastoplastic wall type collisions have two distinct plastic flow regimes that create complex relationships between the yield stress and the responses of the solid bodies.     

Numerical Prediction of Macroscopic Material Failure

The aim of this contribution is the numerical determination of macroscopic material properties based on constitutive relationships characterising the microscale. A macroscopic failure criterion is computed using a three dimensional finite element formulation. The proposed finite element model implements the Strong Discontinuity Approach (SDA) in order to include the localised, fully nonlinear kinematics associated with the failure on the microscale. This numerical application exploits further the Enhanced–Assumed–Strain (EAS) concept to decompose additively the deformation gradient into a conforming part corresponding to a smooth deformation mapping and an enhanced part reflecting the final failure kinematics of the microscale. This finite element formulation is then used for the modelling of the microscale and for the discretisation of a representative volume element (RVE). The macroscopic material behaviour results from numerical computations of the RVE. (© 2006 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim)     

Application and evaluation of hyper- and hypoelastic-based plasticity models in the FE simulation of metal forming processes

Metal forming processes are usually accompanied by large plastic strains and rotations of the material elements which emphasizes the need for reliable finite strain elastoplasticity models in corresponding FE simulations. In this work, two specific finite strain hyper- and hypoelastic-based plasticity models with combined nonlinear isotropic and kinematic hardening are presented and compared in numerical FE simulations. Although both models led to remarkably different results in a shear-dominated single element deformation test, the structural simulation of a standard deep drawing process delivered nearly congruent results which suggests that both models are equally well-suited for modeling metals in common forming processes. (© 2013 Wiley-VCH Verlag GmbH & Co. KGaA, Weinheim)     

A crystal plasticity framework based on the Continuum Dislocation Dynamics theory: relaxation of an idealized micropillar

The motion and interaction of dislocation lines are the physical basis of the plastic deformation of metals. Although ‘discrete dislocation dynamic’ (DDD) simulations are able to predict the kinematics of dislocation microstructure (i.e. the motion of dislocations in a given velocity field) and therefore the plastic behavior of crystals in small length scales, the computational cost makes DDD less feasible for systems larger than a few micro meters. To overcome this problem, the Continuum Dislocation Dynamics (CDD) theory was developed. CDD describes the kinematics of dislocation microstructure based on statistical averages of internal properties of dislocation systems. In this paper we present a crystal plasticity framework based on the CDD theory. It consists of two separate parts: a classical 3D elastic boundary value problem and the evolution of dislocation microstructure within slip planes according to the CDD constitutional equations. We demonstrate the evolution of dislocation density in a micropillar with a single slip plane. (© 2013 Wiley-VCH Verlag GmbH & Co. KGaA, Weinheim)     

A constitutive model for shape memory alloy fibres and its applicability to prestressed composites

This contribution is concerned with a constitutive model for shape memory fibres. The 1D-constitutive model accounts for the pseudoplastic and shape memory effect (SME). The macroscopic answer of the material is determined by the evolution from a twinned martensitic lattice into a deformed and detwinned one. On the macroscopic scale these effects are responsible for the upper boundary of the hysteresis which is situated around the origin of the stress-strain-diagram. During the phase transition process inelastic strains arise. When the lattice is fully detwinned, a linear elastic branch at the end of the hysteresis is observed. The initial state of the material is recovered by unloading and heating the material subsequently. The constitutive model is derived from the Helmholtz' free energy and fulfils the 2nd law of thermodynamics. For the present model five internal state variables are employed. Two of them are used to describe the inelastic strain and a backstress. The others represent the martensitic volume fraction and are necessary to describe the SME. The latter variables are depending on the deformation state as well as on temperature. A change on temperature goes along with a reduction of the inelastic strain. The model is incorporated in a fibre matrix discretization to prestress the surrounding structure. The boundary value problem is solved for a truss element applying the finite element method. Examples will demonstrate the applicability in engineering structures. (© 2011 Wiley-VCH Verlag GmbH & Co. KGaA, Weinheim)