Constitutive equations for metal powders: application to powder forming processes

A new constitutive model for cold compaction of metal powders is developed. The plastic flow of metal powders at the macroscopic level is assumed to be representable as a combination of a distortion mechanism, and a consolidation mechanism. For the distortion mechanism the model employs a pressure-sensitive, Mohr–Coulomb type yield condition, and a new physically based non-associated flow rule. For the consolidation mechanism the model employs a smooth yield function which has a quarter-elliptical shape in the mean-normal pressure and the equivalent shear stress plane, together with an associated flow rule. The constitutive model has been implemented in a finite element program. The material parameters in the constitutive model have been calibrated for MH-100 iron powder by fitting the model to reproduce data from true triaxial compression experiments, torsion ring-shear experiments, and simple compression experiments. The predictive capability of the constitutive model and computational procedure is checked by simulating two simple powder forming processes: (i) a uniaxial strain compression of a cylindrical sample, and (ii) forming of a conical shaped-charge liner. In both cases the predicted load–displacement curves and density variations in the compacted specimens are shown to compare well with corresponding experimental measurements.     

On modeling the micro-indentation response of an amorphous polymer

Interest in instrumented indentation experiments as a means to estimate mechanical properties has grown rapidly in recent years. Although numerous nano/micro-indentation experimental studies on polymeric materials have been reported in the literature, a corresponding methodology for extracting material property information from the experimental data does not exist. This situation for polymeric materials exists primarily because baseline numerical analyses of sharp indentation using appropriate large deformation constitutive models for the nonlinear viscoelastic–plastic response of these materials appear not to have been previously reported in the literature. An existing, widely used theory for amorphous polymers (e.g. [Boyce, M., Parks, D., Argon, A.S., 1988. Large inelastic deformation of glassy polymers. Part 1: Rate dependent constitutive model. Mechanics of Materials 7, 15–33; Arruda, E.M., Boyce, M.C., 1993. Evolution of plastic anisotropy in amorphous polymers during finite straining. International Journal of Plasticity 9, 697–720]) has been recently found to lack sufficient richness to enable one to quantitatively reproduce the major features of the indentation load-versus-depth curves for some common amorphous polymers [Gearing, B.P., 2002. Constitutive equations and failure criteria for amorphous polymeric solids. Ph.D. thesis, Massachusetts Institute of Technology].This study develops a new continuum model for the viscoelastic–plastic deformation of amorphous polymeric solids. We have applied the constitutive model to capture salient features of the mechanical response of the amorphous polymeric solid poly(methyl methacrylate) (PMMA) at ambient temperature and stress states under which this material does not exhibit crazing. We have conducted compression-tension strain-controlled experiments, as well as stress-controlled compression-creep experiments, and these experiments are used to calibrate the material parameters in the constitutive model for PMMA.We have implemented our constitutive model in a finite-element computer program, and using this finite-element program we have simulated micro-indentation experiments on PMMA. We show that our constitutive model and finite element simulations reproduce the experimentally-measured indentation load-versus-depth response with reasonable accuracy.     

Numerical simulation of contraction and expansion flows of Langmuir monolayers

Langmuir monolayers consist of amphiphilic molecules at the air–water interface and can be modeled as two-dimensional fluids. Earlier experiments [D.J. Olson, G.G. Fuller, J. Non-Newtonian Fluid Mech. 89 (2000) 187–207] on 4:1 contraction and 4:1 expansion flows have been simulated using an integral constitutive equation of the K-BKZ type, suitably modified to account for strain-thickening in the planar extensional viscosity. The model has been used to fit linear viscoelastic data (G′ and G″) and the shear viscosity (η_S), while the amount of strain-hardening is assumed, due to lack of experimental data. The simulations are in good agreement with the experiments on Newtonian monolayers, which show no vortices in the contraction but large inertial vortices in the expansion. For the viscoelastic monolayer (a poly-octadecyl methacrylate or PODMA), the opposite is true. The contraction flow shows vortices, while in the expansion flow the vortex activity is substantially reduced compared with the Newtonian one. The viscoelastic behavior is well captured by the model, provided that substantial strain-thickening is exhibited by the monolayer in planar extension. The latter behavior is very much like that for a branched LDPE melt, which also shows big vortices due to strain-hardening in planar as well as in uniaxial extension.     

Thermomechanical behavior of shape memory alloy under complex loading conditions

The thermo-mechanical behavior of polycrystalline shape memory alloy (SMA) under multi-axial loading with varying temperature conditions has been studied by experiments. Recently the research has been extended theoretically and a mechanical model of polycrystalline SMA and the corresponding mesoscopic constitutive equations have been developed. The model presented in this paper is constructed on the basis of the crystal plasticity and the deformation mechanism of SMA. The variants in the crystal grains and the orientations of crystal grains in the polycrystal are considered in the proposed model; the constitutive equations are derived on the basis of the proposed model. The volume fraction of the martensite variants in the transformation process and the influence of the stress state on the transformation process are also considered. Some calculated results obtained by the constitutive equations are presented and compared with the experimental results. It is found that the deformation behavior of SMA under complex loading conditions can be well reproduced by the calculation of the constitutive equations.     

Constitutive modeling of soil-structure interface through the concept of critical state soil mechanics

The behavior of soil-structure interface can be crucial to the overall response of a soil-structure system. The numerical simulation of soil-structure interaction problem requires proper modeling of the interface. The similarity between the behavior of soil and interface is first analyzed in the present paper. With this similarity, the concept of critical state soil mechanics (CSSM), which has been successfully used in the modeling of soil behavior, is used to develop a constitutive model for soil-structure interface in the framework of generalized plasticity. The model is capable of modeling strain hardening, softening, normal dilatancy and stress-path dependency of interface between sandy soil and structures during shearing. The effects of normal pressure as well as density of sand are captured in the model. The performance of the model is verified with various experimental results. The unified modeling of the behavior of interfaces with different roughness, different density of soil and different normal pressures using the concept of CSSM is also successfully attempted.     

Cohesive–frictional interface constitutive model

In the framework of numerical analysis of joined bodies, the present paper is devoted to the constitutive modeling, via an interface kinematic formulation, of mechanical behaviour of internal adhesive layers. The proposed interface constitutive model couples a cohesive behaviour, based on the damage mechanics theory, with a frictional one, defined in a non-associative plasticity framework. Namely, the interface formulation follows the transition of the adhesive material from the sound elastic condition to the fully cracked one. This formulation is able to model, by means of a specific interpretation of the damage variable and in a relevant mathematical setting, the interface intermediate mechanical properties, during the microcracks spreading process up to the discontinuity surface formation (macrocrack). The constitutive modeling is performed in fully compliance with the thermodynamic principles, in order to ensure the thermodynamic consistency requirement. In the present work, various monotonic and cyclic loading conditions are examined in order to show the main features of the constitutive formulation as well as several significant differences with respect to other existing models. Computational efficiency of the interface constitutive model is tested in a numerical application by FEM resolution strategy approach.     

Coupled thermo-mechanical modelling of bulk-metallic glasses: Theory, finite-element simulations and experimental verification

A three-dimensional, finite-deformation-based constitutive model to describe the behavior of metallic glasses in the supercooled liquid region has been developed. By formulating the theory using the principles of thermodynamics and the concept of micro-force balance [Gurtin, M., 2000. On the plasticity of single crystals: free energy, microforces, plastic-strain gradients. J. Mech. Phys. Solids 48, 989-1036], a kinetic equation for the free volume concentration is derived by augmenting the Helmholtz free energy used for a conventional metallic alloy with a flow-defect free energy which depends on the free volume concentration and its spatial gradient. The developed constitutive model has also been implemented in the commercially available finite-element program ABAQUS/Explicit (2005) by writing a user-material subroutine. The constitutive parameters/functions in the model were calibrated by fitting the constitutive model to the experimental simple compression stress-strain curves conducted under a variety of strain-rates at a temperature in the supercooled liquid region [Lu, J., Ravichandran, G., Johnson, W., 2003. Deformation behavior of the Zr-Ti-Cu-Ni-Be bulk metallic glass over a wide range of strain-rates and temperatures. Acta Mater. 51, 3429-3443].With the model calibrated, the constitutive model was able to reproduce the simple compression stress-strain curves for jump-in-strain-rate experiments to good accuracy. Furthermore stress-strain responses for simple compression experiments conducted at different ambient temperatures within the supercooled liquid region were also accurately reproduced by the constitutive model. Finally, shear localization studies also show that the constitutive model can reasonably well predict the orientation of shear bands for compression experiments conducted at temperatures within the supercooled liquid region [Wang, G., Shen, J., Sun, J., Lu, Z., Stachurski, Z., Zhou, B., 2005. Compressive fracture characteristics of a Zr-based bulk metallic glass at high test temperatures. Mater. Sci. Eng. A 398, 82-87].     

VISCOELASTIC MODELLING OF ENTRANCE FLOW USING MULTIMODE LEONOV MODEL

A simulation of planar 2D flow of a viscoelastic fluid employing the Leonov constitutive equation has been presented. Triangular finite elements with lower-order interpolations have been employed for velocity and pressure as well as the extra stress tensor arising from the constitutive equation. A generalized Lesaint–Raviart method has been used for an upwind discretization of the material derivative of the extra stress tensor in the constitutive equation. The upwind scheme has been further strengthened in our code by also introducing a non-consistent streamline upwind Petrov–Galerkin method to modify the weighting function of the material derivative term in the variational form of the constitutive equation. A variational equation for configurational incompressibility of the Leonov model has also been satisfied explicitly. The corresponding software has been used to simulate planar 2D entrance flow for a 4:1 abrupt contraction up to a Deborah number of 670 (Weissenberg number of 6·71) for a rubber compound using a three-mode Leonov model. The predicted entrance loss is found to be in good agreement with experimental results from the literature. Corresponding comparisons for a commercial-grade polystyrene, however, indicate that the predicted entrance loss is low by a factor of about four, indicating a need for further investigation. © 1997 by John Wiley & Sons, Ltd.     

炭黑填充天然橡胶Mullins效应的仿真与计算分析

通过有限元分析软件Abaqus、Matlab数据拟合工具及单轴拉伸试验,研究了Yeoh本构模型、Ogden本构模型及伪弹性理论模型对炭黑填充天然橡胶的Mullins效应仿真效果及规律。结果表明,(1)对单轴拉伸主加载曲线的拟合,Ogden模型精度更高,而Yeoh模型随着炭黑含量的增加在小变形处的拟合效果变差;(2)提出了伪弹性参数与伸长比之间的关系,找到了一种快速计算伪弹性参数的方法,且精度良好,极大地提高了计算效率。     

Constitutive structure in coupled non-linear electro-elasticity: Invariant descriptions and constitutive restrictions

A constitutive framework for electro-sensitive materials in the context of non-linear elasticity is analyzed. Constitutive equations are given in terms of energy functions that depend on several invariants. The study includes both the analysis of the invariants, which are present in the energy functions, and the analysis of constitutive restrictions that have to be obeyed by the constitutive functions. Isotropic as well as non-isotropic electro-sensitive elastomers are studied. The set of invariants that describe each material model is analyzed under two homogeneous deformations: (i) an uniaxial elongation and (ii) a simple shear deformation. These deformations are chosen since they are relevant to specific experiments, from which one may try to fit constitutive equations. The constitutive restrictions developed are based on classical ones used for isotropic non-linear elastic materials, in particular, are based on the Baker–Ericksen inequality and the ellipticity condition.     

Simplified model for prediction of dynamic damage and fracture of ductile materials

A simplified model for prediction of dynamic damage and fracture of ductile material has been proposed. The plastic flow of matrix and the void growth are dealt with separately after we show that two separated loading sub-surfaces and corresponding normality rules for matrix and damage exist. The equation of the loading sub-surface for the matrix plastic flow is derived by the means of introducing a mapping damage-free solid of matrix material, whose constitutive relation is supposed to have been determined via Hopkinson bar experiments. Based on the results of recovered experiments the law of damage evolution is phenomenally established. The model has been applied to predict some spall experiments carried out on tantalum, and results show it predicts the experiments very well.     

Numerical analysis of macrocrack propagation along a bimaterial interface under dynamic loading processes

Advances in computing as well as measurement instrumentation have recently allowed for the investigation of a wider spectrum of physical phenomena in dynamic failure than previously possible. With increasing demand for specialized lightweight, high strength structures, failure of inhomogeneous solids has been receiving increased attention. Such inhomogeneous solids include structural composites such as bonded and sandwich structures, layered and composite materials as well as functionally graded solids. Many of such solids are composed of brittle constituents possessing substantial mismatch in wave speeds, and are bonded together with weak interfaces, which may serve as sites for catastrophic failure (Rosakis and Ravichandran (2000)).In the present study numerical analysis of macrocrack propagation along a bimaterial interface under dynamic loading processes is presented. A general constitutive model of elasto-viscoplastic damaged polycrystalline solids is developed within the thermodynamic framework of the rate type covariance structure with finite set of the internal state variables. A set of the internal state variables is assumed and interpreted such that the theory developed takes account of the effects as follows: (i) plastic non-normality; (ii) softening generated by microdamage mechanisms; (iii) thermomechanical coupling (thermal plastic softening and thermal expansion); (iv) rate sensitivity.To describe suitably the time and temperature dependent effects observed experimentally during dynamic loading processes the kinetics of microdamage has been modified. The relaxation time is used as a regularization parameter. By assuming that the relaxation time tends to zero, the rate independent elastic–plastic response can be obtained. The identification procedure is developed basing on the experimental observations. The finite difference method for regularized elasto-viscoplastic model is used. The edge-cracked bimaterial specimen is considered. In the initial configuration, the height of the specimen is equal to 30 cm, width is 12.5 cm and the length of the initial crack is equal to 2.5 cm. The length of the boundary over which impact is applied is equal to 5 cm, the rise time is fixed at 0.1 μs and the impact velocity is varied. The impact area is localized symmetrically or asymmetrically to the shorter axis of the specimen (symmetry axis of the cohesive band). Basing on the available data of recent experimental observation Rosakis et al. (1999) that have been carried out for relatively thin specimens both the plane stress and plane strain conditions are considered. The material of the specimen is AISI 4340 steel, while PMMA is the cohesive band, both modelled by thermo-elasto-viscoplastic constitutive equations with effects of isotropic hardening and softening generated by microdamage mechanisms and thermomechanical coupling. Fracture criterion based on the evolution of microdamage is assumed. Both, isothermal and adiabatic processes are considered.Particular attention is focused on the investigation of the interactions and reflections of stress waves and the influence of these waves on the propagation of macrocrack within the interface band. The propagation of the macroscopic crack within the material of the interface band for both symmetrical and asymmetrical impact cases has been investigated. It has been found that macrocrack-tip speeds vary from the shear wave speed to the dilatational wave speed of the material and is higher than the Rayleigh surface wave speed. This result is in accord with the experimental observations performed by Rosakis et al. (1999).     

微孔洞唯象损伤力学模型及其应用

基于微损伤发展的NAG(nucleation and growth)模型,从唯相角度,得到了一种微孔洞损伤演化方程。在考虑损伤软化和温度软化的基础上得到了材料含损伤本构关系。将损伤演化方程和材料本构关系引入ABAQUS有限元软件对D6AC和921两种钢板撞击层裂问题进行数值模拟。模拟结果与实验结果吻合。     

A plasticity model for interface friction: application to sheet metal forming

Successful numerical simulations of forming operations require robust and accurate tool-workpiece interface friction models. In this paper we extend the rate-independent, isotropic, isothermal interface friction model proposed by Anand (Anand, L., 1993. A constitutive model for interface friction. Computational Mechanics 12, 197–213) to a rate-dependent formulation. Material parameters in the friction model are determined for lubricated interfaces between Al6111-T4 sheet and D2 tool steel. The lubricants used are MP404 and boric acid; the MP404 lubricant is currently used in industry, whereas boric acid has recently been proposed as a solid-film lubricant for sheet forming by Erdemir (Erdemir, A., 1991. Tribological properties of boric acid and boric acid-forming surfaces. Part i: crystal chemistry and mechanisms of self-lubrication of boric acid. Lubrication Engineering 47, 168–173). The interface friction model is implemented in the finite element code ABAQUS/Explicit (ABAQUS Reference Manual., 1999. Providence, RI), and the finite element program is used to simulate two sheet forming operations: axisymmetric cup-drawing and square pan-drawing. The predictions from the finite element simulation are shown to be in very good agreement with experimental results.     

An analytical model to predict residual thermal stress in 2D orthogonal plain weave fabric composites

This paper seeks to address a practical rectangular truss model to predict residual thermal stress in a 2 D plain weave fabric (PWF) composite. The two orthogonal yarns in a micromechanical unit cell are idealized as straight rods subjected to tensile or compression loading resulting in extension or shortening deformation. The residual thermal stresses and equivalent thermal expansion coefficients in a PWF layer are derived from the thermal constitutive equations and the deformation compatibility condition. Based on the deformation compatibility equations, the thermal constitutive relationships for PWF composites are obtained to derive the residual thermal stresses between PWF plies and pure resin. In order to validate the model, experiments have been performed to investigate the mechanical properties of two-dimensional (2D) orthogonal EW220/5284 PWF composites fabricated by resin transfer moulding (RTM). It is shown that the experimental results correlate well with predictions from the new model.     

Strong discontinuity analysis of a class of anisotropic continuum damage constitutive models – Part II: Concrete material application

On the basis of the strong discontinuity analysis, a discrete model expressed in terms of traction vector-displacement jump has been constructed from a continuous model expressed in terms of stress–strain law. In the first part of the paper, this approach has been extended to a class of anisotropic continuum damage constitutive models [1]. In this second part of the paper, the proposed class of discrete anisotropic damage constitutive models is particularized. More precisely, a micromechanical-based anisotropic damage constitutive model is derived. This model accounts in a natural manner for particular crack families orientation. The aims of this paper are (i) to illustrate the capabilities of the proposed discrete enhanced model in reproducing the induced anisotropy appearing in quasi-brittle materials when cracking and (ii) to assess the numerical robustness of the time integration scheme. For this purpose, two numerical examples at the material point level are exposed after a brief presentation of the time integration scheme. The correspondence between the continuous and the discrete model as well as the induced anisotropy features are emphasized.     

Evaluation of identification methods for YLD2004-18p

Four calibration methods have been evaluated for the linear transformation-based anisotropic yield function YLD2004-18p (Barlat, F., Aretz, H., Yoon, J.W., Karabin, M.E., Brem, J.C., Dick, R.E., 2005. Linear transformation-based anisotropic yield functions. Int. J. Plasticity 21, 1009–1039) and the aluminium alloy AA5083-H116. The different parameter identifications are based on least squares fits to combinations of uniaxial tensile tests in seven directions with respect to the rolling direction, compression (upsetting) tests in the normal direction and stress states found using the full-constraint (FC) Taylor model for 690 evenly distributed strain paths. An elastic–plastic constitutive model based on YLD2004-18p has been implemented in a non-linear finite element code and used in finite element simulations of plane-strain tension tests, shear tests and upsetting tests. The experimental results as well as the Taylor model predictions can be satisfactorily reproduced by the considered yield function. However, the lacking ability of the Taylor model to quantitatively reproduce the experiments calls for more advanced crystal plasticity models.     

Complex unloading behavior: Nature of the deformation and its consistent constitutive representation

Complex (nonlinear) unloading behavior following plastic straining has been reported as a significant challenge to accurate springback prediction. More fundamentally, the nature of the unloading deformation has not been resolved, being variously attributed to nonlinear/reduced modulus elasticity or to inelastic/“microplastic” effects. Unloading-and-reloading experiments following tensile deformation showed that a special component of strain, deemed here “Quasi-Plastic-Elastic” (“QPE”) strain, has four characteristics. (1) It is recoverable, like elastic deformation. (2) It dissipates work, like plastic deformation. (3) It is rate-independent, in the strain rate range 10⁻⁴-10⁻²/s, contrary to some models of anelasticity to which the unloading modulus effect has been attributed. (4) To first order, the evolution of plastic properties occurs during QPE deformation. These characteristics are as expected for a mechanism of dislocation pile-up and relaxation. A consistent, general, continuum constitutive model was derived incorporating elastic, plastic, and QPE deformation. Using some aspects of two-yield-function approaches with unique modifications to incorporate QPE, the model was implemented in a finite element program with parameters determined for dual-phase steel and applied to draw-bend springback. Significant differences were found compared with standard simulations or ones incorporating modulus reduction. The proposed constitutive approach can be used with a variety of elastic and plastic models to treat the nonlinear unloading and reloading of metals consistently for general three-dimensional problems.