3D dynamic modeling of powder forming processes via a simple and efficient node-to-surface contact algorithm

In this paper, a simple and efficient contact algorithm is presented for the evaluation of density distribution in three-dimensional dynamic modeling of powder compaction processes. The contact node-to-surface algorithm is employed to impose the contact constraints in large deformation frictional contact, and the contact frictional slip is modified by the Coulomb friction law to simulate the frictional behavior between the rigid punch and the work-piece. The 3D nonlinear contact friction algorithm is employed together with a double-surface cap plasticity model within the framework of large finite element deformation in order to predict the non-uniform relative density distribution during the dynamic simulation of powder die-pressing. The accuracy and robustness of contact algorithm is verified by the impact analysis of two elastic rods, which is compared with the analytical solution. Finally, the performance of computational schemes is illustrated in dynamic modeling of a set of powder components.     

Finite element simulation for dynamic large elastoplastic deformation in metal powder forming

In this paper, a transient dynamic analysis of the powder compaction process is simulated by a large displacement finite element method based on a total and updated Lagrangian formulation. A combination of the Mohr–Coulomb and elliptical yield cap model, which reflects the stress state and degree of densification, is applied to describe the constitutive model of powder materials. A Coulomb friction law and a plasticity theory of friction in the context of an interface element formulation are employed in the constitutive modelling of the frictional behaviour between the die and powder. Finally, the powder behaviour during the compaction of a plain bush, a rotational flanged and a shaped tip component are analysed numerically. It is shown that the updated Lagrangian formulation, using a combination of the Mohr–Coulomb and elliptical cap model, can be effective in simulating metal powder compaction.     

Formulation and analysis of two energy-consistent methods for nonlinear elastodynamic frictional contact problems

Energy-conserving algorithms are necessary to solve nonlinear elastodynamic problems in order to recover long term time integration accuracy and stability. Furthermore, some physical phenomena (such as friction) can generate dissipation; then in this work, we present and analyse two energy-consistent algorithms for hyperelastodynamic frictional contact problems which are characterised by a conserving behaviour for frictionless impacts but also by an admissible frictional dissipation phenomenon. The first approach permits one to enforce, respectively, the Kuhn–Tucker and persistency conditions during each time step by combining an adapted continuation of the Newton method and a Lagrangean formulation. In addition the second method which is based on the work in [P. Hauret, P. Le Tallec, Energy-controlling time integration methods for nonlinear elastodynamics and low-velocity impact, Comput. Methods Appl. Mech. Eng. 195 (2006) 4890–4916] represents a specific penalisation of the unilateral contact conditions. Some numerical simulations are presented to underscore the conservative or dissipative behaviour of the proposed methods.     

A Hybrid Micro­Macro­Model for the Description of Evolving Anisotropy in Finite Polycrystal Plasticity

The paper outlines recent developments of an efficient computational micro-macro modeling of evolving anisotropies in metallic polycrystals. Main focus is put onto large strain deformation processes where the anisotropy is caused by developments of crystallographic texture. We construct a hybrid micro-macro framework that mixes ingredients of a purely macroscopic modeling with scale bridging operations of selected micromechanisms. On the micromechanical side, we develop a new algorithmic procedure to capture the crystal reorientation for evolving fcc and bcc textures based on a parametrization of rotations in the Rodigues space. The computational model provides a fast and robust method for the estimation of evolving textures. This computational tool for texture estimation is incorporated in a modular format into a micro-macro-model, where it governs the evolution of macrostructural tensors due to texture development. The general framework for the hybrid embedding is a purely phenomenological setting of anisotropic finite plasticity in the logarithmic strain space. The model provides an efficient and computationally handable two-scale approach for the prediction of effects caused by complex microstructural changes in polycrystals. The capability of the proposed method is demonstrated by means of representative numerical examples. (© 2010 Wiley-VCH Verlag GmbH & Co. KGaA, Weinheim)     

Analysis and numerical solution of a piezoelectric frictional contact problem

We consider a mathematical model which describes the frictional contact between an electro-elastic–visco-plastic body and a conductive foundation. The contact is modelled with normal compliance and a version of Coulomb’s law of dry friction, in which the stiffness and the friction coefficients depend on the electric potential. We derive a variational formulation of the problem and we prove an existence and uniqueness result. The proof is based on a recent existence and uniqueness result on history-dependent quasivariational inequalities obtained in [15]. Then we introduce a fully discrete scheme for solving the problem and, under certain solution regularity assumptions, we derive an optimal order error estimate. Finally, we present some numerical results in the study of a two-dimensional test problem which describes the process of contact in a microelectromechanical switch.     

A consistent implementation for inelastic materials in an ALE formulation for steady state rolling contact

The numerical analysis of rolling contact for rubber materials is a challenging task, especially due to the many nonlinearities inherent to the material, large deformations, friction, and energy dissipation, among others. Industrial applications can be found in ball bearings, rollers, and most commonly in tires of vehicles, applications where reliable numerical simulations lead to the improvement of durability, performance and safety. While a transient analysis stands as a practical and powerful tool for the simulation of rotating bodies, the large amount of computational resources required represents its biggest disadvantage. An alternative frequently used lays in a steady state simulation by means of an Arbitrary Lagrangian Eulerian (ALE) formulation, where the rotational velocity and axial loads are assumed to remain constant. Within this framework, the reference configuration is neither attached to the material particles nor fixed in space and special attention should be paid to the history variables of inelastic materials. In this work, a viscoelastic material model is implemented in an in-house finite element code, based on a generalized Maxwell model. The implementation takes into consideration the contribution of all elements connected in circumferential direction and a consistent linearization is made for each of them, leading to an assembled stiffness matrix with more non-zero values than a standard one. This approach is combined with smeared reinforcement embedded in base elements. The reinforcing layers are described by a hyperelastic material model, providing additional advantages for the modeling and simulation of reinforced rollers and tires. Numerical results for different examples show the capabilities of this implementation and the efficiency of the numerical algorithms is discussed. Important remarks and an outlook for further research concludes this presentation. (© 2016 Wiley-VCH Verlag GmbH & Co. KGaA, Weinheim)     

T-splines discretizations for large deformation contact problems

A T-spline-based isogeometric analysis is applied to frictional contact problems between deformable bodies in the context of large deformations. The continuum is discretized with cubic T-splines and cubic NURBS (Non-Uniform Rational B-Splines) for comparison purposes. A Gauss-point-to-surface (GPTS) formulation is combined with the penalty method to treat the normal and friction contact constraints in the discretized setting. It is demonstrated that the proposed formulation combined with analysis-suitable T-spline interpolations, is a computationally accurate and efficient technology for local and global solutions of contact problems. T-spline analysis models are generated using commercially available T-spline modeling software without intermediate mesh generation or geometry clean-up steps. (© 2015 Wiley-VCH Verlag GmbH & Co. KGaA, Weinheim)     

Modeling frictional contact in shell structures using variational inequalities

A new variational inequality-based formulation is presented for the large deformation analysis of frictional contact in shell structures. This formulation is based on a seven-parameter continuum shell model which accounts for the normal stress and strain through the shell thickness and accommodates double-sided shell contact. The kinematic contact conditions are expressed accurately in terms of the physical contacting surfaces of the shell. Furthermore, Lagrange multipliers are used to ensure that the kinematic contact constraints are accurately satisfied and that the solution is free from user-defined parameters. Large deformations and rotations are accounted for by invoking the Piola–Kirchhoff stress and the Green–Lagrange strain measures. Three examples involving a strip friction test, ring contact and sheet compression tests are used to verify the developed formulations and algorithms, and test various aspects of the solution technique. Photoelastic analysis of the ring compression example is performed for experimental verification.     

Variational and numerical analysis of a quasistatic viscoelastic problem with normal compliance,friction and damage

We consider a model for quasistatic frictional contact between a viscoelastic body and a foundation. The material constitutive relation is assumed to be nonlinear. The mechanical damage of the material, caused by excessive stress or strain, is described by the damage function, the evolution of which is determined by a parabolic inclusion. The contact is modeled with the normal compliance condition and the associated version of Coulomb's law of dry friction. We derive a variational formulation for the problem and prove the existence of its unique weak solution. We then study a fully discrete scheme for the numerical solutions of the problem and obtain error estimates on the approximate solutions.     

Micro‐ and nanoscale modelling of dry friction with application to the wheel/rail contact

Friction is a phenomenon involving elastic interactions, plastic deformation and failure processes at different length scales. A model of dry friction is established based on the method of Movable Cellular Automata (MCA). The influence of material and loading parameters has been investigated within a large number of numerical simulations. The new friction law is applied to the calculation of stresses, deformations and tractive forces in wheel/rail contact with rough surfaces. (© 2004 WILEY‐VCH Verlag GmbH & Co. KGaA, Weinheim)     

Development of a finite element model of metal powder compaction process at elevated temperature

This paper presents the finite element modelling of metal powder compaction process at elevated temperature. In the modelling, the behaviour of powder is assumed to be rate independent thermo-elastoplastic material where the material constitutive laws are derived based on a continuum mechanics approach. The deformation process of metal powder has been described by a large displacement based finite element formulation. The Elliptical Cap yield model has been used to represent the deformation behaviour of the powder mass during the compaction process. This yield model was tested and found to be appropriate to represent the compaction process. The staggered-incremental-iterative solution strategy has been established to solve the non-linearity in the systems of equations. Some numerical simulation results were validated through experimentation, where a good agreement was found between the numerical simulation results and the experimental data.     

Hydraulic hysteresis effects on the coupled flow–deformation processes in unsaturated soils: Numerical formulation and slope stability analysis

The hysteresis of water retention curve has a profound influence on the coupled hydro-mechanical behaviors in unsaturated soils, but numerical implementation with consideration of this property was rarely reported due to the difficulties in the integration of the coupled constitutive models. In this study, a numerical formulation is proposed for modeling the coupled flow–deformation processes with hydraulic hysteresis. A return mapping scheme is developed to integrate the water retention curve model with hydraulic hysteresis and the elasto-plastic model simultaneously within a time step, and the deformation-dependent nature of the water retention curve is considered rigorously by modifying the coefficient matrices in the discretized governing equations. The performance and efficiency of the proposed numerical formulation is validated by two existing laboratory tests and a computational example, demonstrating better performance and convergence of the proposed formulation. The proposed procedure is then applied for modeling the coupled flow–deformation processes in a soil slope under rain infiltration. The simulated results reveal the significant effects of hydraulic hysteresis on the coupled water–air two-phase flow and elasto-plastic deformation processes. The solid deformation and the evolution of the shear band would be remarkably overestimated, and the slope failure would be early predicted when neglecting hydraulic hysteresis.     

Analysis of contact-impact dynamics of soft finger tapping system by using hybrid computational model

The aim of this paper is to develop an efficient hybrid computational model to analyze the frictional impact dynamic responses of soft finger during the tapping event. The large deformation field and inertial field of soft structure are discretized by absolute nodal coordinate formulation. Lagrange multiplier method is adopted to account for the constraints between neighbor phalanges. Considering tangential contact compliance, a lumped-parameter model at the local contact zone is presented to calculate contact forces. The governing equations of soft finger tapping system expressed by generalized coordinates are derived. An event driven scheme is given to analyze and evaluate the stick–slip transitions. The governing equation is integrated by generalized-α method. The applications of the hybrid computational model are demonstrated using various soft finger tapping systems acted by different driven moments. The feasibility of the proposed model is validated by comparing with the LS-DYNA solution. The error of the solution calculated by the proposed model for the peak value of contact force is less than 8%. Furthermore, numerical results show that the large structural compliance and driven moments have significant effect on the frictional impact responses. The normal relative motion between the fingertip and the rough target surface will experience 1∼4 compression-restitution transitions when Young's Modulus is from 0.01 GPa to 1 GPa or the slenderness ratio of phalanx is from 10.7 to 32. When the posture of soft finger is convex at impact instance, the tangential relative motion will experience 3 slip–stick transitions during the contact process. In addition, it also can be found that the tangential contact compliance can reverse the direction of slip (i.e. ‘reverse slip’ phenomenon).     

Quasistatic frictional thermo‐piezoelectric contact problem

We consider here a mathematical model describing the bilateral frictional contact between a thermo‐piezoelectric body and a thermally conductive foundation. We model the behavior of the material with a linear thermo‐electro‐elastic constitutive law. The process is assumed to be quasistatic and the contact is modeled with a nonlocal version of Coulomb's dry friction law, in which the frictional heat generated in the process, is taken into account. We drive a variational formulation of the problem and establish the existence of its weak solution.     

Multiscale simulation for description of rubber friction

The interaction between tire and road generates the transferable forces, which are necessary for driving dynamics and safety. These forces are based on friction between rubber material and pavement surface and depend on the roughness of the pavement, the slip velocity, the contact pressure and the temperature. Based on the finite element method, the friction coefficient is calculated by numerical simulation. The roughness of the pavement surface is described by the height difference correlation function (HDCF), which allows partitioning into different length scales. This multiscale approach is suitable to understand and to evaluate friction phenomena. These phenomena are hysteresis friction based on dissipation inside the rubber material and adhesion friction, which describes the direct bonding between two materials. Given, that the material parameters of rubber highly depend on temperature and the frictional dissipation leads to a warming of the rubber, the provision for these effects is necessary for a realistic desciption of friction. The method allows an understanding of friction phenomena on the micro-scale like the real contact area or the microscopic contact pressure. Also, the temperature distribution inside the tire cross-section can be illustrated. The resulting coefficient of friction is validated by experimental data based on linear friction tests and compared to analytical solutions. (© 2016 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)     

Analysis of a dynamic contact problem for electro-viscoelastic cylinders

We consider a mathematical model which describes the antiplane shear deformations of a piezoelectric cylinder in frictional contact with a foundation. The process is mechanically dynamic and electrically static, the material behavior is described with a linearly electro-viscoelastic constitutive law, the contact is frictional and the foundation is assumed to be electrically conductive. Both the friction and the electrical conductivity condition on the contact surface are described with subdifferential boundary conditions. We derive a variational formulation of the problem which is of the form of a system coupling a second order hemivariational inequality for the displacement field with a time-dependent hemivariational inequality for the electric potential field. Then we prove the existence of a unique weak solution to the model. The proof is based on abstract results for second order evolutionary inclusions in Banach spaces. Finally, we present concrete examples of friction laws and electrical conductivity conditions for which our result is valid.