Experimental evaluation and constitutive modeling of non-proportional deformation for asymmetric steels

Recently non-proportional deformation has received increased attention from researchers working in the area of experimental and computational modeling of metal deformation. However, most of them are numerical in nature with limited experimental data available, making it further difficult to model non-proportional deformation. In the present work, two-stage uniaxial tests, along with uniaxial cyclic and biaxial tests for different stress ratios, have been performed to evaluate deformation behavior of ultra-low carbon high strength automotive steel. Behaviors like cross-effect and hardening stagnation, which are attributed to the evolution of complex dislocation structures, were observed in this steel. It was also noticed that this steel exhibits tension-compression asymmetry. As for constitutive modeling, a modified asymmetric yield function is proposed to be used with a combined isotropic-kinematic hardening model. Also methods to account for the hardening stagnation during reverse loading and the cross-effect during two-stage deformation are proposed. The resulting constitutive model showed reasonably good agreement with experimental results.     

Anisotropic plasticity for sheet metals using the concept of combined isotropic-kinematic hardening

Hill's 1948 anisotropic theory of plasticity (Hill, R., 1948. A theory of yielding and plastic flow of anisotropic metals. Proc. Roy. Soc. London A193, 281–297) is extended to include the concept of combined isotropic-kinematic hardening, and the objective of this paper is to validate the model so that it may be useful for analyses of sheet metal forming. Isotropic hardening and kinematic hardening may be experimentally observed in sheet metals, if yielding is defined by the proportional limit or by a small proof strain. In this paper, a single exponential term is used to describe isotropic hardening and Prager's linear kinematic hardening rule is applied for simplicity. It is shown that this model can satisfactorily describe both the yield stress and the plastic strain ratio, the R-ratio, observed in tension test of specimens cut at various angles measured from the rolling direction of the sheet. Kinematic hardening leads to a gradual change in the direction of the plastic strain increment, as the axial strain increases in the tension test; while in the traditional approach for sheet metal, this direction does not change due to the use of isotropic hardening.     

Exact integration of the von Mises elastoplasticity model with combined linear isotropic-kinematic hardening

The main purpose of this work is to present two semi-analytical solutions for the von Mises elastoplasticity model governed by combined linear isotropic-kinematic hardening. The first solution (SOLε) corresponds to strain-driven problems with constant strain rate assumption, whereas the second one (SOLσ) is proposed for stress-driven problems using constant stress rate assumption. The formulas are derived within the small strain theory Besides the new analytical solutions, a new discretized integration scheme (AMε) based on the time-continuous SOLε is also presented and the corresponding algorithmically consistent tangent tensor is provided. A main advantage of the discretized stress updating algorithm is its accuracy; it renders the exact solution if constant strain rate is assumed during the strain increment, which is a commonly adopted assumption in the standard finite element calculations. The improved accuracy of the new method (AMε) compared with the well-known radial return method (RRM) is demonstrated by evaluating two simple examples characterized by generic nonlinear strain paths.     

Anisotropic hardening and non-associated flow in proportional loading of sheet metals

Conventional isotropic hardening models constrain the shape of the yield function to remain fixed throughout plastic deformation. However, experiments show that hardening is only approximately isotropic under conditions of proportional loading, giving rise to systematic errors in calculation of stresses based on models that impose the constraint. Five different material data for aluminum and stainless steel alloys are used to calibrate and evaluate five material models, ranging in complexity from a von Mises’ model based on isotropic hardening to a non- associated flow rule (AFR) model based on anisotropic hardening. A new model is described in which four stress–strain functions are explicitly integrated into the yield criterion in closed form definition of the yield condition. The model is based on a non-AFR so that this integration does not affect the accuracy of the plastic strain components defined by the gradient of a separate plastic potential function. The model not only enables the elimination of systematic errors for loading along the four loading conditions, but also leads to a significant reduction of systematic errors in other loading conditions to no higher than 1.5% of the magnitude of the predicted stresses, far less that errors obtained under isotropic hardening, and at a level comparable to experimental uncertainty in the stress measurement. The model is expected to lead to a significant improvement in stress prediction under conditions dominated by proportional loading, and this is expected to directly improve the accuracy of springback, tearing, and earing predictions for these processes. In addition, it is shown that there is no consequence on MK necking localization due to the saturation of the yield surface in pure shear that occurs with the aluminum alloys using the present model.     

A combined isotropic-kinematic hardening model for the simulation of warm forming and subsequent loading at room temperature

A coupled isotropic-kinematic hardening material model was developed based on phenomenological observations of performed two stage experiments on a medium carbon steel – SAE 1144, where the first deformation is performed at elevated temperatures and the second deformation at room temperature. Above all, deformations with orthogonal loading at various temperatures were investigated in order to determine the influence of the loading direction as well as of the temperature. Bergström’s theory of work hardening as well as the nonlinear kinematic hardening of an Armstrong–Frederick type were used as a basis for the model development. In the proposed model a relationship between material coefficients of the classical Bergström model and temperature was investigated. The aim of the new material model was to introduce the least possible amount of new parameters as well as to facilitate the mathematical determination of parameters during the fitting of the model with experimental data. The developed model was implemented in an in-house FE-Code in order to simulate the material behavior due to the dynamic strain aging and the hardening behavior after the dynamic strain aging process. Representative simulation results were compared with the experimental data in order to validate the efficiency and the application range of the model.     

Experimental investigation of the behavior of extra high strength steel

This paper comprises a study concerning the mechanical behavior of extra high strength steel. This is investigated by means of biaxial testing of flat cross-shaped specimens in the full σ₁-σ₂ plane, a concept developed earlier at Steel Structures, Luleå University of Technology. Furthermore, new specimen designs had to be developed to enable testing of a material with high yield strength and low ultimate over yield strength ratio, such as the extra high strength steel Weldox 1100. The tests are performed in two steps: one initial loading followed by unloading and a subsequent loading in a new direction. The test results, containing data from 15 biaxial tests, are characterized by a slightly anisotropic initial yield criterion where the proof stress in compression is consequently somewhat higher compared to the results in tension. In the subsequent loading the observed phenomena are a Bauschinger effect in the direction opposite the initial loading direction and that the transition from elastic to plastic state in subsequent loadings is gradual and direction-dependent.     

A simple isotropic-distortional hardening model and its application in elastic–plastic analysis of localized necking in orthotropic sheet metals

In the present work an elastic–plastic constitutive model including mixed isotropic-distortional hardening is presented. The approach is very simple and requires only experimental data that are part of the standard characterization of sheet metals. It is shown that the distortional hardening contribution can be of considerable importance for localized necking prediction in orthotropic sheet metals.     

Experimental investigation and modeling of the tension behavior of polycarbonate with temperature effects from low to high strain rates

The effects of strain rate and temperature on the tension stress–strain responses of polycarbonate are experimentally investigated over a wide range of strain rates (0.001–1700 s⁻¹) and temperatures (0–120 °C). A modified split Hopkinson tension bar is used for high-rate uniaxial tension tests. Experimental results indicate that the stress–strain responses of polycarbonate at high strain rates exhibit the nonlinear characteristics including the obvious yielding and strain softening. The tension behavior is strongly dependent on the strain rate and temperature. The values of yield stress and strain at yield present a dramatic increase at higher strain rates and decrease with the increase in temperature. Moreover, there exists a significant rate-sensitivity transition in the polycarbonate tension yield behavior. Based on the experimental investigation, a physically based three-dimensional elastoplastic constitutive model for the finite deformation of glassy polymers is used to characterize the rate-temperature dependent yield and post-yield behavior of polycarbonate when subjected to tension loading. The model results are shown close to the experimental data within the investigated strain-rate and temperature ranges.     

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.     

Characterization of plunging liquid jets: A combined experimental and numerical investigation

This paper presents a combined experimental and numerical study of the flow characteristics of round vertical liquid jets plunging into a cylindrical liquid bath. The main objective of the experimental work consists in determining the plunging jet flow patterns, entrained air bubble sizes and the influence of the jet velocity and variations of jet falling lengths on the jet penetration depth. The instability of the jet influenced by the jet velocity and falling length is also probed. On the numerical side, two different approaches were used, namely the mixture model approach and interface-tracking approach using the level-set technique with the standard two-equation turbulence model. The numerical results are contrasted with the experimental data. Good agreements were found between experiments and the two modelling approaches on the jet penetration depth and entraining flow characteristics, with interface tracking rendering better predictions. However, visible differences are observed as to the jet instability, free surface deformation and subsequent air bubble entrainment, where interface tracking is seen to be more accurate. The CFD results support the notion that the jet with the higher flow rate thus more susceptible to surface instabilities, entrains more bubbles, reflecting in turn a smaller penetration depth as a result of momentum diffusion due to bubble concentration and generated fluctuations. The liquid average velocity field and air concentration under tank water surface were compared to existing semi-analytical correlations. Noticeable differences were revealed as to the maximum velocity at the jet centreline and associated bubble concentration. The mixture model predicts a higher velocity than the level-set and the theory at the early stage of jet penetration, due to a higher concentration of air that cannot rise to the surface and remain trapped around the jet head. The location of the maximum air content and the peak value of air holdup are also predicted differently.     

Experimental and numerical investigation of turbulent cross-flow in a staggered tube bundle

This paper presents the results of measurements and numerical predictions of turbulent cross-flow in a staggered tube bundle. The bundle consists of transverse and longitudinal pitch-to-diameter ratios of 3.8 and 2.1, respectively. The experiments were conducted using a particle image velocimetry technique, in a flow of water in a channel at a Reynolds number of 9300 based on the inlet velocity and the tube diameter. A commercial CFD code, ANSYS CFX V10.0, is used to predict the turbulent flow in the bundle. The steady and isothermal Reynolds–Averaged Navier–Stokes (RANS) equations were used to predict the turbulent flow using each of the following four turbulence models: a k-epsilon, a standard k-omega, a k-omega-based shear stress transport, and an epsilon-based second moment closure. The epsilon-based models used a scalable wall function and the omega-based models used a wall treatment that switches automatically between low-Reynolds and standard wall function formulations.

The experimental results revealed extremely high levels of turbulence production by the normal stresses, as well as regions of negative turbulence production. The convective transport by mean flow and turbulent diffusion were observed to be significantly higher than in classical turbulent boundary layers. As a result, turbulence production is generally not in equilibrium with its dissipation rate. In spite of these characteristics, it was observed that the Reynolds normal stresses approximated from the k-based two-equation models were in a closer agreement with experiments than values obtained from the second moment closure. The results show that none of the turbulence models was able to consistently reproduce the mean and turbulent quantities reasonably well. The omega-based models predicted the mean velocities better in the developing region while the epsilon-based models gave better results in the region where the flow is becoming spatially periodic.     

泡沫铝铜合金静态压缩力学行为和吸能性能的实验研究

通过静态压缩实验研究一种新型闭孔泡沫铝材料泡沫铝铜合金的静态压缩力学行为和吸能性能。对实验得到的一定密度范围内的材料的弹性模量E和平台应力pl关于相对密度进行曲线拟合,发现将Gibson等给出的开孔泡沫理论公式中的幂次常数修正为由实验确定的常数,可以给出一定密度范围的闭孔泡沫铝铜合金材料的弹性模量和平台应力与相对密度之间关系的一个较好的估计。采用比能-应力或比能-应变曲线,可以对不同密度的泡沫铝铜合金材料的吸能情况进行较为直观的比较和分析。该曲线对工程设计具有较好的指导意义。     

Experimental analysis and modeling of biaxial mechanical behavior of woven composite reinforcements

This paper presents experimental studies on the mechanical behavior of fiber fabrics using a biaxial tensile device based on two deformable parallelograms. The cross-shaped specimens are well adapted to fabrics because of their lack of shear stiffness. Tension versus deformation curves, for different strain ratios, are obtained in the case of composite woven reinforcements used in aeronautic applications. It is shown that the tensile behavior of the fabric is strongly nonlinear due to the weaving undulations and the yarn contraction, and that the phenomenon is clearly biaxial. A constitutive model is described and identified from the experimental data. The essential role played by the yarn crushing will be pointed out.     

爆轰波通过扩张喷管的双曝光全息实验和数值研究

结合实验和数值模拟方法,对以脉冲爆轰发动机为背景的爆轰波通过扩张喷管的流动进行了系列研究。实验采用双曝光全息干涉方法对爆轰波绕射流场进行测量,得到了比传统的纹影法更清晰和可定量化的照片。发展了基于非结构四边形网格自适应有限体积程序,结合基元化学反应模型对扩张喷管中爆轰化学反应流场进行了数值模拟,模拟结果与实验照片吻合较好。实验和数值模拟结果表明,爆轰波绕射具有许多和激波绕射不同的流场特征,其中包括二次起爆现象、化学反应面与前导激波相脱离而引起的复杂流场等,同时初始压力和扩张角度变化也对爆轰波绕射过程产生较大影响,初始压力越低,化学反应区和前导激波分离现象越明显,且前导激波的曲率越大。     

Identification of the plastic behavior of aluminum plates under free air explosions using inverse methods and full-field measurements

This article describes an inverse method for the identification of the plastic behavior of aluminum plates subjected to sudden blast loads. The method uses full-field optical measurements taken during the first milliseconds of a free air explosion and the finite element method for the numerical prediction of the blast response. The identification is based on a damped least-squares solution according to the Levenberg–Marquardt formulation. Three different rate-dependent plasticity models are examined. First, a combined model based on linear strain hardening and the strain rate term of the Cowper–Symonds model, secondly, the Johnson–Cook model and finally, a combined model based on a bi-exponential relation for the strain hardening term and the strain rate term of the Cowper–Symonds model. A validation of the method and its sensitivity to measurement uncertainties is first provided according to virtual measurements generated with the finite element method. Next, the plastic behavior of aluminum is identified using measurements from real free air explosions obtained from a controlled detonation of C4. The results show that inverse methods can be successfully applied for the identification of the plastic behavior of metals subjected to blast waves. In addition, the material parameters identified with inverse methods enable the numerical prediction of the material’s response with increased accuracy.