Cohesive fracture simulation and failure modes of FRP–concrete bonded interfaces

A work-of-fracture method using three-point bend beam (3PBB) specimen, commonly employed to determine the fracture energy of concrete, is adapted to evaluate the mode-I cohesive fracture of fiber reinforced plastic (FRP) composite–concrete adhesively bonded interfaces. In this study, a bilinear damage cohesive zone model (CZM) is used to simulate cohesive fracture of FRP–concrete bonded interfaces. The interface cohesive process damage model is proposed to simulate the adhesive–concrete interface debonding; while a tensile plastic damage model is used to account for the cohesive cracking of concrete near the bond line. The influences of the important interface parameters, such as the interface cohesive strength, concrete tensile strength, critical interface energy, and concrete fracture energy, on the interface failure modes and load-carrying capacity are discussed in detail through a numerical finite element parametric study. The results of numerical simulations indicate that there is a transition of the failure modes controlling the interface fracture process. Three failure modes in the mode-I fracture of FRP–concrete interface bond are identified: (1) complete adhesive–concrete interface debonding (a weak bond), (2) complete concrete cohesive cracking near the bond line (a strong bond), and (3) a combined failure of interface debonding and concrete cohesive cracking. With the change of interface parameters, the transition of failure modes from interface debonding to concrete cohesive cracking is captured, and such a transition cannot be revealed by using a conventional fracture mechanics-based approach, in which only an energy criterion for fracture is employed. The proposed cohesive damage models for the interface and concrete combined with the numerical finite element simulation can be used to analyze the interface fracture process, predict the load-carrying capacity and ductility, and optimize the interface design, and they can further shed new light on the interface failure modes and transition mechanism which emulate the practical application.     

Integrated numerical–experimental analysis of interfacial fatigue fracture in SnAgCu solder joints

In ball grid array (BGA) packages, solder balls are exposed to cyclic thermo-mechanical strains arising from the thermal mismatch between package components. Thermo-mechanical fatigue crack propagation in solder balls is almost always observed at the chip side of the bump/pad junction. The objective of the experimental part of this study is to characterize the bump/pad interface under fatigue loading. Fatigue specimens are prepared by reflowing Sn3.8Ag0.5Cu lead-free solder alloy on Ni/Au substrates. Obtained results show that fatigue damage evolution strongly depends on the microstructure. Applied strain and solder volume both have an influence on the fatigue damage mechanism. In the numerical part of the study, fatigue experiments are modeled using the finite element technique. A cohesive zone approach is used to predict the fatigue damage evolution in soldered connections. Crack propagation is simulated by an irreversible linear traction–separation cohesive zone law accompanied by a non-linear damage parameter. Cohesive zone elements are placed where failure is experimentally observed. Damage evolution parameters for normal and tangential interaction are scrutinized through dedicated fatigue tests in pure tensile and shear directions. The proposed cohesive zone model is quantitatively capable of describing fatigue failure in soldered joints, which can be further extended to a numerical life-time prediction tool in microelectronic packages.     

Fatigue damage modeling in solder interconnects using a cohesive zone approach

The objective of this work is to model the fatigue damage process in a solder bump subjected to cyclic loading conditions. Fatigue damage is simulated using the cohesive zone methodology. Damage is assumed to occur at interfaces modeled through cohesive zones in the material, while the bulk material is assumed to be linear elastic. The state of damage at a cohesive zone is incorporated into the cohesive zone constitutive law by a elasticity-based damage variable. The gradual degradation of the solder material and the corresponding damage accumulation throughout the cycling process is accounted for by a damage evolution law which captures the main damage characteristics. The model prediction of the solder bump life-time is shown to be in good agreement with one of the commonly used empirical life-time prediction laws.     

Cohesive zone model for high-cycle fatigue of adhesively bonded joints under mode I loading

A cohesive zone model adequate for simulating the behaviour of adhesively bonded joints subjected to high-cycle fatigue and pure mode I loading is presented. The bilinear cohesive zone law with linear softening relationship was considered. The main advantage of the proposed formulation is the use of a unique damage parameter accounting for cumulative damage resulting from static and fatigue loading. The method was implemented in a user subroutine of the commercial finite element software Abaqus®. Two-dimensional numerical simulations of the double cantilever beam test using different representative combinations of the modified Paris law coefficients were performed. It was verified that the results of the model simulate with excellent agreement the several Paris laws used as input, thus demonstrating the good performance of the method as a predictive tool.     

Delamination mechanism maps for a strong elastic coating on an elastic–plastic substrate subjected to contact loading

Hard wear resistant coatings that are subjected to contact loading sometimes fail because the coating delaminates from the substrate. In this report, systematic finite element computations are used to model coating delamination under contact loading. The coating and substrate are idealized as elastic and elastic–plastic solids, respectively. The interface between coating and substrate is represented using a cohesive zone law, which can be characterized by its strength and fracture toughness. The system is loaded by an axisymmetric, frictionless spherical indenter. We observe two failure modes: shear cracks may nucleate just outside the contact area if the indentation depth or load exceeds a critical value; in addition, tensile cracks may nucleate at the center of the contact when the indenter is subsequently removed from the surface. Delamination mechanism maps are constructed which show the critical indentation depth and force required to initiate both shear and tensile cracks, as functions of relevant material properties. The fictitious viscosity technique for avoiding convergence problems in finite element simulations of crack nucleation and growth on cohesive interfaces allows us to explore a wider parametric space that a conventional cohesive model cannot handle. Numerical results have also been compared to analytical analyses of asymptotic limits using plate bending and membrane stretching theories, thus providing guidelines for interpreting the simulation results.     

基于损伤-虚拟张拉裂纹模型的地下爆炸围岩破坏规律研究

地下硐室作为爆炸危险物的隐蔽贮藏空间,有潜在的内爆炸风险。为研究内爆炸作用下硐室围岩的动态响应机制,提出了一种基于岩石HJC (Holmquist-Johnson-Cook)模型和节理内聚力单元的损伤-虚拟裂纹模型。分析了模拟方法的可靠性,并在此基础上,通过多物质ALE算法对球形硐室内爆炸过程进行数值模拟,分析了围岩损伤范围和分区破坏规律。研究表明：插入内聚力单元弥补了HJC模型无法模拟低静水压力下张拉破坏的不足,且尺寸效应易于处理。模拟方法同时考虑了岩体内张拉裂纹的扩展和岩石材料的塑性损伤,能够真实地反映岩石破坏的全过程。以红砂岩为例,根据数值模拟结果,填实（耦合装药）爆炸时围岩分区破坏规律明显,破碎区比例半径为0.26 m/kg^1/3、裂隙区比例半径为0.47 m/kg^1/3。随着硐室尺寸的增大,空气的间隔作用可以减小爆炸荷载对围岩的损伤作用,比例半径达到0.52 m/kg^1/3时,可以实现爆炸荷载的完全解耦。

     

Interface damage and its effect on vibrations of slab track under temperature and vehicle dynamic loads

This paper presents a three-dimensional finite element model to investigate the interface damage occurred between prefabricated slab and CA (cement asphalt) mortar layer in the China Railway Track System (CRTS-II) slab track system. In the finite element model, a cohesive zone model with a non-linear constitutive law is introduced and utilized to model the damage, cracking and delamination at the interface. Combining with the temperature field database obtained from the three-dimensional transient heat transfer analysis, the interface damage evolution as a result of temperature change is analyzed. A three-dimensional coupled dynamic model of a vehicle and the slab track is then established to calculate the varying rail-supporting forces which are utilized as the inputs to the finite element model. The non-linearities of the wheel–rail contact geometry, the wheel–rail normal contact force and the wheel–rail tangential creep force are taken into account in the model. Setting the maximum interface damaged state calculated under temperature change as the initial condition, the interface damage evolution and its influence on the dynamic response of the slab track are investigated under the joint action of the temperature change and vehicle dynamic load. The analysis indicates that the proposed model is capable of predicting the initiation and propagation of cracks at the interface. The prefabricated slab presents lateral warping, resulting in severe interface damage on both the sides of the slab track along the longitudinal direction during temperature drop process, while the interface damage level does not change significantly under vehicle dynamic loads. The interface damage has great effects on the dynamic responses of the slab track.     

Cohesive zone laws for void growth — II. Numerical field projection of elasto-plastic fracture processes with vapor pressure

Modeling ductile fracture processes using Gurson-type cell elements has achieved considerable success in recent years. However, incorporating the full mechanisms of void growth and coalescence in cohesive zone laws for ductile fracture still remains an open challenge. In this work, a planar field projection method, combined with equilibrium field regularization, is used to extract crack-tip cohesive zone laws of void growth in an elastic-plastic solid. To this end, a single row of void-containing cell elements is deployed directly ahead of a crack in an elastic-plastic medium subjected to a remote K-field loading; the macroscopic behavior of each cell element is governed by the Gurson porous material relation, extended to incorporate vapor pressure effects. A thin elastic strip surrounding this fracture process zone is introduced, from which the cohesive zone variables can be extracted via the planar field projection method. We show that the material's initial porosity induces a highly convex traction-separation relationship — the cohesive traction reaches the peak almost instantaneously and decreases gradually with void growth, before succumbing to rapid softening during coalescence. The profile of this numerically extracted cohesive zone law is consistent with experimentally determined cohesive zone law in Part I for multiple micro-crazing in HIPS. In the presence of vapor pressure, both the cohesive traction and energy are dramatically lowered; the shape of the cohesive zone law, however, remains highly convex, which suggests that diffusive damage is still the governing failure mechanism.     

Modeling shale with consideration of bedding planes by cohesive finite element method

Shale contains distributed directional bedding planes, which make the shale transverse isotropic.To model shale with consideration of the bedding planes, a cohesive finite element method(CFEM) is developed based on the randomized triangular mesh. The interface orientation generated from such mesh tends to be uniformly distributed with the element number increasing.To represent the bedding plane, the interfaces aligned with the bedding plane are assigned the cohesive law that characterizes the bedding plane while the other interfaces are assigned the cohesive law that characterizes the matrix. By this means, the anisotropy characteristics of the stiffness and the strength of shale are well represented. The simulation examples demonstrate that the bedding plane has a significant influence on the fracture trajectory, which is consistent with the observation in the experiment. It is suggested that this modeling method of shale is feasible. It provides an alternative approach to fracture simulation in shale.     

Cohesive zone laws for fatigue crack growth: Numerical field projection of the micromechanical damage process in an elasto-plastic medium

Cohesive zone failure models are widely used to simulate fatigue crack propagation under cyclic loading, but the model parameters are phenomenological and are not closely tied to the underlying micromechanics of the problem. In this paper, we will inversely extract the cohesive zone laws for fatigue crack growth in an elasto-plastic ductile solid using a field projection method (FPM), which projects the equivalent tractions and separations at the cohesive crack-tip from field information outside the process zone. In our small-scale yielding model, a single row of discrete voids is deployed directly ahead of a crack in an elasto-plastic medium subjected to cyclic mode I K-field loading. Damage accumulation under cyclic loading is captured by the growth of voids within the micro-voiding zone ahead of the crack, while the evolution of the cohesive zone law representing the micro-voiding zone is inversely extracted via the FPM. We show that the field-projected cohesive zone law captures the essential micromechanisms of fatigue crack growth in the ductile medium: from loading and unloading hysteresis caused by void growth and plastic hardening, to the softening damage locus associated with crack propagation via a void by void growth mechanism. The results demonstrate the effectiveness of the FPM in obtaining a micromechanics-based cohesive zone law in-place of phenomenological models, which opens the way for a unified treatment of fatigue crack problems.     

考虑粘结面厚度的局部粘结单元法

传统无厚度粘结单元法CFEM (Cohesive finite element method)在模拟脆性材料断裂方面具有很强的优势,但也存在很大问题.一是单元尺寸增大,收敛性变差;二是单元尺寸变小,模型刚度发生折减.为了克服这两个问题,发展了考虑厚度的局部粘结单元法,即在裂纹可能扩展区插入具有一定厚度的粘结面单元.粘结面单元采用拓展虚内键本构(Augmented virtual internal bond)描述.由于考虑了厚度,粘结面交叉处会形成多边形空缺.为了弥补这一空缺,将其看作多边形键元胞,采用离散虚内键模型(Discretized virtual internal bond)对其建模,保证了模型的几何完整性.模拟结果表明,本文方法有效,克服了传统CFEM方法的刚度折减问题,提高了计算稳定性和收敛性.     

损伤演化对韧性金属碎裂过程的影响

固体在冲击拉伸载荷作用下会断裂成多个碎片,基于线性内聚力断裂假设的Mott-Grady模型能较好地预测碎裂过程所产生的平均碎片尺度的下限。然而实际上,韧性金属的损伤演化是多元化的,为此通过数值模拟方法研究了不同损伤演化规律对韧性碎裂过程的影响。利用ABAQUS/Explicit动态有限元软件数值再现了韧性金属杆（45钢）在高应变率下拉伸碎裂的过程,分析了线性和非线性损伤演化对韧性碎裂过程的影响规律。结果表明：损伤演化规律对韧性金属的碎裂过程具有显著影响,非线性指标α越大,碎裂过程产生的碎片数越少;Grady-Kipp碎裂公式仍能在一定范围内预测韧性碎裂过程中产生的碎片尺寸;当非线性指标α远大于零时,在较低冲击拉伸载荷作用下,数值模拟结果和Grady-Kipp模型预测值偏差较大,随着应变率增大,数值模拟结果与Grady-Kipp模型预测值吻合较好。

     

On a geometrically nonlinear damage model based on a multiplicative decomposition of the deformation gradient and the propagation of microcracks

We aim to derive a damage model for materials damaged by microcracks. The evolution of the cracks shall be governed by the maximum energy release rate, which was recently shown to be a direct consequence of the variational principle of a body with a crack (Arch. Appl. Mech. 69 (5) (1999) 337). From this, we get the path of the growing crack by introducing a series of thermodynamically equivalent straight cracks. The equivalence of the energy dissipated by microcrack growth and the damage dissipation leads to our damage evolution law. This evolution law will be embedded in a finite deformation framework based on a multiplicative decomposition into elastic and damage parts. As a consequence of this, we can present the anisotropic damaged elasticity tensor with the help of push and pull operations. The connection of this approach to other well known damage theories will be shown and the advantages of a finite element framework will be worked out. Numerical examples show the possibilities of the proposed model.     

粘结单元在模拟FRP层合板低速冲击响应中的应用

纤维增强树脂基复合材料层合板(fibre reinforced plastic composites,FRP)在航空、航天、交通、造船等诸多工程中得到了日益广泛的应用,而其在冲击载荷下的响应和破坏特别是分层一直为学术界所关注。本文中对FRP层合板在冲击载荷下的响应和破坏进行数值模拟,并通过引入粘结层重点研究其分层破坏。首先,介绍一种基于改进的粘结区域方法的粘结层损伤模型;其次,详细介绍了有限元模型建模过程和建模细节;最后,对有限元模型进行验证,并分析分层损伤发生的原因。模拟结果表明,该模型不仅能准确预测FRP层合板在低速冲击载荷下的载荷-时间曲线和载荷-位移曲线,还能成功地预测其分层破坏。     

Theoretical development and experimental validation of a thermally dissipative cohesive zone model for dynamic fracture of amorphous polymers

A thermally dissipative cohesive zone model is developed for predicting the temperature increase at the tip of a crack propagating dynamically in a nominally brittle material exhibiting a cohesive-type failure such as crazing. The model assumes that fracture energy supplied to the crack tip region that is in excess of that needed for the creation of new free surfaces during crack advance is converted to heat within the cohesive zone. Bulk dissipation mechanisms, such as plasticity, are not accounted for. Several cohesive traction laws are examined, and the model is then used to make predictions of crack tip heating at various crack propagation speeds in the nominally brittle amorphous polymer PMMA, observed to fail by a crazing-type mechanism. The heating predictions are compared to experimental data where the temperature field surrounding a high speed crack in PMMA was measured. Measurements are made in real time using a multi-point high speed HgCdTe infrared radiation detector array. At the same time as temperature, simultaneous measurement of fracture energy is made by a strain gauge technique, and crack tip speed is monitored through a resistance ladder method. Material strength can be estimated through uniaxial tension tests, thus minimizing the need for parameter fitting in the stress-opening traction law. Excellent agreement between experiments and theory is found for two of the cohesive traction law temperature predictions, but only for the case where a single craze is active during the dynamic fracture of PMMA, i.e. crack tip speed up to approximately 0.2c_R. For higher speed fracture where subsurface damage becomes prominent, the line dissipation model of a cohesive zone is inadequate, and a distributed damage model is needed.     

Nonlinear progressive damage model for composite laminates used for low-velocity impact

In order to effectively describe the progressively intralaminar and interlam- inar damage for composite laminates, a three dimensional progressive damage model for composite laminates to be used for low-velocity impact is presented. Being applied to three-dimensional （3D） solid elements and cohesive elements, the nonlinear damage model can be used to analyze the dynamic performance of composite structure and its failure be- havior. For the intralaminar damage, as a function of the energy release rate, the damage model in an exponential function can describe progressive development of the damage. For the interlaminar damage, the damage evolution is described by the framework of the continuum mechanics through cohesive elements. Coding the user subroutine VUMAT of the finite element software ABAQUS/Explicit, the model is applied to an example, i.e., carbon fiber reinforced epoxy composite laminates under low-velocity impact. It is shown that the prediction of damage and deformation agrees well with the experimental results.     

短柱型复合材料加筋壁板轴向压缩破坏分析方法研究

复合材料加筋结构可作为航空结构中的承力部件,其损伤与破坏对航空器的结构安全和服役性能至关重要。本文通过试验和数值仿真手段研究了短柱型复合材料结构压缩失效机理和极限承载力。通过短柱型单加筋板的轴向压缩破坏试验,分析梳理出界面脱粘和材料压溃两种典型失效形式;分别建立加筋板壳单元模型和实体单元模型,引入内聚力模型和Hashin准则描述界面脱粘效应与材料破坏,结果表明壳单元模型配合内聚力模型和Hashin准则可以有效地预测加筋板的极限承载力。分别讨论了加筋板长度、筋条高度、筋条/蒙皮刚度比等参数对加筋板的屈曲承载力的影响,为短柱型复合材料加筋壁板压缩损伤与破坏预测分析提供有益的参考。