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)     

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)     

About the Microstructural Effects of Polycrystalline Materials and their Macroscopic Representation at Finite Deformation

In the sheet bulk metal forming field, the strict geometrical requirements of the workpieces result in a need of a precise prediction of the material behaviour. The simulation of such forming processes requires a valid material model, performing well for a huge variety of different geometrical characteristics and finite deformation. 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 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. The validation on the macroscopic scale is performed through the reproduction of the experimentally calculated initial yield surface. Additionally, homogenised stress-strain curves from the microstructure build the outcome for a suitable effective material model. Through optimisation techniques, effective material parameters can be determined and compared to results from real forming processes. (© 2012 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)     

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)     

Multiscale modelling and simulation of micro machining of titanium

The microscale morphology of micro machined component surfaces is directly connected to the heterogeneous microstructure. The deformation depends on the crystal structure, in case of the considered cp-titanium, the hcp crystal structure. In a first approach the crystal plastic deformation is modeled with isotropic hardening. A visco-plastic evolution law accounts for the rate dependency. The concept of configurational forces is used with the framework of crystal plasticity to model the cutting process of cp-titanium. The setting is implemented into the finite element method. The examples show the effect of the material heterogeneity on the deforamtion behavior and on the related configurational forces. (© 2012 Wiley-VCH Verlag GmbH & Co. KGaA, Weinheim)     

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)     

Validation of Material Models in Grain Scale Simulation based on EBSD Experimental Data

A crystal plasticity model and a homogenization method are used to analyze the local and global mechanical behavior of a ferritic stainless steel. In the first step the material constants are determined based on tensile tests and used to simulate the local deformation behavior on the grain scale in the second step. For that 2D EBSD data are discretized by finite elements. The computed local grain reorientations of three different BCC slip systems are compared to experimental data at the state of 20% elongation. (© 2011 Wiley-VCH Verlag GmbH & Co. KGaA, Weinheim)     

率相关晶体塑性模型的塑性各向异性分析

在Sarma和Zacharia的工作基础上,改进了单晶晶体弹粘塑性本构模型的积分算法,并采用改进的欧拉法结合迭代方法求解,特点是稳定性好计算效率较高．然后用上述模型及算法研究了:1）在单向拉伸和平面应变压缩变形下单晶塑性各向异性的特点;2）晶体模型中的主要材料参数（应变率敏感指数m和潜硬化比率q）和加载应变率对单晶塑性各向异性的影响;3）沿不同的晶体方向加载对滑移系启动的影响．     

Configurational Forces in Cutting Processes of Microstructured Titanium

The micro cutting process of microstructured material is influenced by the heterogeneity of the microstructure. In case of cp-titanium an hcp crystal structure is present. Therefore the material response is described with elastic anisotropy and crystal plasticity with the prismatic and basal slip systems of cp-titanium. Also self and latent hardening are considered. The rate dependency is taken into account by a visco-plastic evolution law. In order to investigate a micro cutting process the concept of configurational forces for standard dissipative media is used. Within the finite element method an example illustrates the effects of the heterogeneity and the grain boundary on the configurational force. (© 2014 Wiley-VCH Verlag GmbH & Co. KGaA, Weinheim)     

Anisotropic multiplicative elastoplasticity for the prediction of earings in sheet forming

In this work, the simulation of earings in cup drawing by means of a recently developed anisotropic combined hardening material model is discussed. The model represents a multiplicative formulation of anisotropic elastoplasticity in the finite strain regime with nonlinear kinematic and isotropic hardening. Plastic anisotropy is described by the use of second-order structure tensors as additional arguments in the representation of the yield function and the plastic flow rule. The evolution equations are integrated by a form of the exponential map that preserves the plastic volume and the symmetry of the internal variables. Finite element simulations of cylindrical cup drawing processes are performed by means of ABAQUS/Standard where the discussed material model has been implemented into a user-defined reduced integration solid-shell element. (© 2010 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)     

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)     

Microstructural behaviour of transversal isotropic material

We discuss and simulate transversal isotropic material under tension loading. The preferential direction of the material is inclined under 45 degrees to the direction of the tensile resultant. In this configuration the deformation of a rectangular test specimen differ from the behaviour of isotropic material in the way, that beside Poissons effect additional displacement appear perpendicular to the tension direction. In classical continuum theories, this transverse deformations describe a typical S–shape. By using a non–local continuum theory, the effect of microstructural orientation is incorporated into the numerical model. Then, it depends on a phenomenological parameter of inner structure whether the energetically favoured configuration is classical or contains microstructural behaviour. In the second case, the transverse deformation is not described by the typical S–shape, but with higher forms of it. A simple experimental model will show the connection between the inner structure of the material and the rotational parameters within the non–local continuum theory. It is evident, that these parameters are responsible for the non–classical behaviour and give the possibility to find energetically favoured solutions. The results of the finite–element–analyses can help to understand constitutive parameters for the non–local continuum theory and to apply it to other specimens. (© 2008 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim)     

A finite element model of localized deformation in frictional materials taking a strong discontinuity approach

A finite element model of localized deformation in frictional materials taking a strong discontinuity approach is presented. A rate-independent, non-associated, strain-softening Drucker–Prager plasticity model is formulated in the context of strong discontinuities and implemented along with an enhanced quadrilateral element within the framework of an assumed enhanced strain finite element method. For simple model problems such as uniform compression, the strong discontinuity approach has been shown to lead to mesh-independent finite element solutions when localized deformation is present. In this paper, a finite element analysis of localized deformation occurring in a more complex model problem of slope stability is conducted in a nearly mesh-independent manner. The effect of dilatancy on the orientation of slip lines is demonstrated for the slope stability problem.     

Particle Finite Element Simulations of Cutting Processes in Manufacturing

The cutting of metals is an important process in manufacturing and challenges established methods in the field of computational mechanics. The particle finite element method (PFEM) combines the benefits of particle based methods and the standard finite element method (FEM) to account for large deformations and separation of material. In cutting simulations the workpiece is realised as a set of particles, whose boundary is detected by the α-shape method. After the boundary detection, the particles are meshed with finite elements. Since metals show a plastic behavior under large deformations, a suitable material model needs to be considered. Numerical examples show the effect of the choice of the parameter α on the cutting force. (© 2016 Wiley-VCH Verlag GmbH & Co. KGaA, Weinheim)     

Damage and fracture behavior in dynamic tension tests: Modelling and numerical simulations

The continuum damage model is based on a general thermodynamic framework for the modeling of rate and temperature dependent behavior of anisotropically damaged elastic-plastic materials subjected to fast deformation. The introduction of damaged and fictitious undamaged configurations allows the definition of damage tensors and the corresponding free energy functions lead to material laws affected by damage and temperature. The damage condition and the corresponding damage rule strongly depend on stress triaxiality. Furthermore, the rate and temperature dependence is reflected in a multiplicative decomposition of the plastic hardening and damage softening functions. The macro crack behavior is characterized by a triaxiality dependent fracture criterion. The continuum damage model is implemented into LS-DYNA as user defined material model. Corresponding numerical simulations of unnotched and notched tension tests with high strain rates demonstrate the plastic and damage processes during the deformation leading to final fracture numerically predicted by an element erosion technique. (© 2011 Wiley-VCH Verlag GmbH & Co. KGaA, Weinheim)