A new computational algorithm for contact friction modeling of large plastic deformation in powder compaction processes

In this paper, the large deformation frictional contact of powder forming process is modeled based on a new computational algorithm by imposing the contact constraints and modifying the contact properties of frictional slip. A simple and efficient numerical algorithm is presented for imposing the contact constraints and frictional contact properties based on the node-to-surface contact technique to simulate the large deformation contact problem in the compaction process of powder. The Coulomb friction law is used to simulate the friction between the rigid punch and the workpiece by the use of penalty approach. A double-surface cap plasticity model is employed together with the nonlinear contact friction algorithm within the framework of large FE deformation in order to predict the non-uniform relative density distribution during large deformation of powder die-pressing. Finally, the numerical schemes are examined for accuracy and efficiency in modeling of a set of powder components.     

Experimental and numerical analysis of fretting crack formation based on 3D X-FEM frictional contact fatigue crack model

Nowadays, numerical simulation of 3D fatigue crack growth is easily handled using the eXtended Finite Element Method coupled with level set techniques. The finite element mesh does not need to conform to the crack geometry. Most difficulties associated to complex mesh generation around the crack and the re-meshing steps during the possible propagation are hence avoided. A 3D two-scale frictional contact fatigue crack model developed within the X-FEM framework is presented in this article. It allows the use of a refined discretization of the crack interface independent from the underlying finite element mesh and adapted to the frictional contact crack scale. A stabilized three-field weak formulation is also proposed to avoid possible oscillations in the local solution linked to the LBB condition when tangential slip is occurring. Two basic three-dimensional numerical examples are presented. They aim at illustrating the capacities and the high level of accuracy of the proposed X-FEM model. Stress intensity factors are computed along the crack front. Finally an experimental 3D ball/plate fretting fatigue test with running conditions inducing crack nucleation and propagation is modeled. 3D crack shapes defined from actual experimental ones and fretting loading cycle are considered. This latter numerical simulation demonstrates the model ability to deal with challenging actual complex problems and the possibility to achieve tribological fatigue prediction at a design stage based on the fatigue crack modeling.     

Modeling of the metal powder compaction process using the cap model. Part I. Experimental material characterization and validation

In order to produce crack free metal powder compacts that respect both the dimensional tolerances and the mechanical strength requirements, both tooling design and compaction sequence have to be adequately determined. The finite element method, through the use of an appropriate constitutive model of the powder medium, has recently been used as an efficient design tool. The accuracy of this method highly depends on the faithfulness of the constitutive model and the quality of the material parameter set. Furthermore, in order for the simulation results to be reliable, they should be experimentally validated on real parts featuring density variations. Hence, the main concerns of this paper are the development of a standard calibration procedure for the cap material model as well as the development of a reliable technique for the experimental validation of the powder compaction simulation results.The developed calibration procedure, applied for the case of 316L stainless steel powders, is based on a series of isostatic, triaxial and uniaxial compaction tests as well as resonant frequency tests. In addition, a sensitivity study was performed in order to determine the relative importance of each factor and basic simulations served to validate the parameter set extraction procedure.On the other hand, a local density measurement technique was developed for the experimental validation of the model results. This technique is based on correlation with Vickers macro-hardness. Finally, an application featuring the compaction of a 316L stainless steel cylindrical component is presented to illustrate the predictive capabilities of the cap material model as well as the accuracy of the acquired material parameter set.     

成形过程数值模拟的张量时空求解策略

成形过程的数值模拟和分析涉及几何、材料、接触摩擦等高度非线性的耦合作用，采用传统的增量算法会导致巨大计算量。本文建议采用张量时间函数的非增量时空算法，在整个时间和空间域上迭代求解。由于采用新的分离变量构思，以张量表达时间函数，可提高问题求解的速度和精度。但对问题的列式和数值求解方法提出了更高的要求。文中讨论其方法与数值实施。     

Imperfection and burial-depth sensitivity of the initiation and development of kink folds in laminated rocks

The first objective is to study the influence of the burial depth and of an imperfection, in the form of a tilt in the inclination of the otherwise straight, laminated beam, on the conditions for the initiation and the development of kink folds. The beam, typical of sedimentary rocks, is layered with weak interfaces between the competent beds, promoting the onset of kinking by their slip. The results are analytical and based on the upper bound approach of the classical limit analysis, referred to as the maximum strength theorem in the absence of any discussion of plasticity. The weak interface strength is described by the Coulomb criterion, whereas the bulk material is also cohesive and frictional but with an additional closure in the compressive stress domain to depict the action of compacting deformation mechanisms. The new twist to the methodology is to extend its application to the development of the failure mode beyond the onset, assuming that the structure finite response is well described by the least upper bound solution. The second objective is to compare in terms of upper bounds three different failure mechanisms which are the compaction band, the reverse fault and the kink fold. Their respective domain of dominance is constructed in failure-mechanism maps in the space spanned by the imperfection angle and the burial depth.Compaction bands are predicted at the deepest end of the beam and the reverse fault and the kink fold at the shallower end. These depth differences are resulting from the geometrical imperfection. It is found that the kink-band mode at its onset, with compaction band dominant conditions, resembles to a slip-enhanced compaction band due to the weak interface activation and the compaction along the two parallel hinges. This hybrid mode migrates suddenly through the competent beam from the deepest towards the shallowest region and develops as a kink fold, after a negligible amount of shortening. The kink fold development, beyond the onset, occurs in two phases, the first corresponding to the rotation of the kink band and the second, to its widening. The associated least upper bound is first decreasing during the development and then increasing, the minimum being controlled more by the increase in the potential energy of the system than by the most favorable orientation of the frictional weak interfaces. It is finally found that the continuous activation of slip over the weak interfaces and the widening of the kink band prevent the rotation of the kink towards the large angles which are necessary to induce its locking. It is proposed that the introduction of damage along the hinges could palliate these two effects and prompt the locking observed experimentally and in the field.     

Extended finite element method for fretting fatigue crack propagation

In this paper, the extended finite element method (X-FEM) is considered for the analysis of fretting fatigue problems. A two-dimensional implementation of the X-FEM is carried out within the finite element software ABAQUS? by means of user subroutines, and crack propagation in fretting fatigue problems is investigated. On utilizing the non-linear contact capabilities of this code, the numerical technique is applied to a specimen-indenter model. The use of the X-FEM facilitates very accurate stress intensity factor computations on relatively coarse meshes, and furthermore, no remeshing is required for crack growth simulations. The implementation is applied to complete and incomplete contact fretting problems. A study of crack growth is conducted for several bulk loads applied to the specimen, and the influence of the initial crack angle is ascertained. The numerical simulations reveal the merits of applying the X-FEM to fretting fatigue problems.     

A continuous material law for modeling thin-sheet piles and their frictional connection

In the present paper, the mechanical modeling and the numerical simulation of a pile of thin sheets under compressive and in-plane forces is presented. These sheets are not glued or laminated, but interact through frictional contact only. In applications, as for example the core of a large power transformer, such piles may consist of thousands of sheets, which are of thickness below 1 mm, while the dimensions of the pile reaches several meters. Also, several piles may interact by a frictional connection. Such connections are realized by regions where sheets from both stacks overlap mutually. Simulations using a properly meshed original geometry and standard finite element models lead to billions of unknowns for industrial applications. Additionally, the system is highly nonlinear due to the heavily coupled contact conditions posed on thousands of interfaces. Simulations become extremely expensive in terms of both memory and computation time, if not even unsolvable due to numerical convergence problems. The aim of this paper is to present a macroscopic material model, which can be applied to an equivalent homogenized computational domain representing the interconnected sheet piles. An extension of the material law in regions of mutual overlapping due to frictional connections is provided. When using the present approach, the homogenized computational domain can be discretized by a far smaller number of unknowns, while a good overall accuracy is retained. The numerical solution of standardized test problems is presented and verified against analytical considerations.     

有限长界面裂纹对冲击载荷的响应

本文研究了受冲击载荷作用下界面裂纹的瞬态特性。通过引入裂纹尖端附近裂纹面无摩擦接触区,消除了界面裂纹问题中存在的振荡奇异性。由于产生了随时间变化的运动边界,应用积分变换及路径积分方法进行反演,在时间-空间域上给出了问题的控制积分方程。应用chebyshev多项式展开,将问题转化为非线性微分-积分方程组的求解。给出了剪切应力强度因子和裂纹面接触区尺寸的数值结果。所得结果表明,拉伸场中界面裂纹的扩展和剪切失效有密切关系。     

Numerical simulation of density distribution during compaction of iron powders

Summary The compaction process of iron powder is considered. Due to negligible elastic strains the rigid-plastic model is applied. A yield condition containing the first stress invariant is used. All material functions depend on the relative density of the powder, which changes during the compaction process. Siebel friction law is applied, and the friction factor is considered to be depending on the relative density. Various material functions are applied in the numerical simulation, and the results are compared with experimentally obtained data. The best fitting material functions and friction factors are obtained. Accepted for publication 18 July 1996     

温成形摩擦界面粉末润滑层宏微观特性的试验研究

温成形时加入润滑剂,可提高产品质量,降低变形力,延长模具的使用寿命.不同温度下润滑剂的性能不同,也影响加工界面的摩擦特性.通过将松散的石墨粉导入到面接触摩擦副间隙中,可以在轴向载荷和剪切力作用下形成减摩性能良好的粉末层,实现高温和高压成形过程的良好润滑.采用多功能摩擦磨损试验机研究温度对温成形粉末润滑界面的影响,对粉末润滑润滑的摩擦副表面进行电子显微镜观察、三维轮廓分析、能谱分析、元素含量分析及拉曼分析,获得温度影响温成形摩擦特性的现象和机理.结果表明:温度对温成形中粉末润滑界面的摩擦特性有很大影响,不同温度下摩擦系数发生改变,而粉末润滑层的平整性、完整性以及石墨有序化程度也随温度改变,而这些因素都是温度改变粉末润滑效果的内在原因.     

压电涂层-功能梯度压电界面层-基底结构的二维接触问题研究

在多层压电元件中,由于界面处材料成分和性质的突变,常常导致界面处应力集中,使得界面处出现开裂或蠕变现象,从而大大缩短了压电元件的使用寿命。功能梯度压电材料作为界面层,可有效的缓解界面材料不匹配导致的破坏。本文主要研究利用功能梯度压电材料界面层连接压电涂层和基底,分析三层结构在圆柱型压头作用下的力电响应。利用傅里叶积分变换技术,本文将压电涂层-功能梯度压电层-基底结构在刚性圆柱压头作用下的二维平面应变接触问题转化为带有柯西核的奇异积分方程。运用高斯-切比雪夫积分公式,将奇异积分方程转化为线性方程组并对其进行数值求解,得到压电涂层-功能梯度压电层-基底结构在圆柱形压头作用下的应力分布和电位移分布。数值结果表明,梯度压电材料参数的变化对结构中的力电响应具有重要的影响。本文研究结果对于利用功能梯度压电界面层消除界面处的应力不连续导致的界面破坏具有重要的理论指导意义,研究结果可为功能梯度压电材料界面层的设计提供帮助。     

混凝土三维细观接触面模型数值模拟与CT试验验证

对混凝土三维随机骨料模型进行了改进,在骨料和砂浆之间加入了"面-面接触单元"模拟两者的接触特性,编制了相应的命令程序,称新模型为混凝土接触面模型.采用双折线损伤演化模型进行计算,对数值模拟结果进行了分析研究.从混凝土破坏过程图和荷载-位移曲线图两方面与CT试验结果进行了比较,表明试件破坏时裂纹的萌生、扩展过程与CT试验...     

An Extended-FEM Model for CO2 Leakage Through a Naturally Fractured Cap-Rock During Carbon Dioxide Sequestration

In this paper, a numerical model is developed for the assessment of carbon dioxide transport through naturally fractured cap-rocks during CO₂ sequestration in underground aquifers. The cap-rock contains two types of fracture with different length scales: micro-cracks (fissures) and macro-cracks (faults). The effect of micro-cracks is incorporated implicitly by modifying the intrinsic permeability tensor of porous matrix, while the macro-cracks are modeled explicitly using the extended finite element method (X-FEM). The fractured porous medium is decomposed into the porous matrix and fracture domain, which are occupied with two immiscible fluid phases, water and CO₂. The flow inside the matrix domain is governed by the Darcy law, while the flow within the fracture is modeled using the Poiseuille flow. The mass conservation law is fulfilled for each fluid phase at both porous matrix and fracture domain; moreover, the mass exchange between the matrix and fracture is guaranteed through the integral formulation of mass conservation law. Applying the X-FEM technique, the explicit representation of macro-cracks is modeled by enriching the standard finite element approximation space with an enrichment function. Finally, several numerical examples of CO₂ injection into a brine aquifer below a naturally fractured cap-rock are modeled in order to investigate the effects of cracks’ aperture and orientation as well as the temperature of aquifer and the depth of injection on the leakage pattern of the carbon dioxide through the cap-rock.

     

A frictional mortar contact approach for the analysis of large inelastic deformation problems

A multibody frictional mortar contact formulation (Gitterle et al., 2010) is extended for the simulation of solids undergoing finite strains with inelastic material behavior. The framework includes the modeling of finite strain inelastic deformation, the numerical treatment of frictional contact conditions and specific finite element technology. Several well-established and recent models are employed for each of these building blocks to capture the distinct physical aspects of the deformation behavior. The approach is based on a mortar formulation and the enforcement of contact constraints is realized with dual Lagrange multipliers. The introduction of nonlinear complementarity functions into the frictional contact conditions combined with the global equilibrium leads to a system of nonlinear equations, which is solved in terms of the semi-smooth Newton method. The resulting method can be interpreted as a primal–dual active set strategy (PDASS) which deals with contact nonlinearities, material and geometrical nonlinearities in one iterative scheme. The consistent linearization of all building blocks of the framework yields a robust and highly efficient approach for the analysis of metal forming problems. The effect of finite inelastic strains on the solution behavior of the PDASS method is examined in detail based on the complementarity parameters. A comprehensive set of numerical examples is presented to demonstrate the accuracy and efficiency of the approach against the traditional node-to-segment penalty contact formulation.     

Mechanism-based strain gradient Drucker–Prager elastoplasticity for pressure-sensitive materials

Modeling strain gradient plasticity effects has achieved considerable success in recent years. However, incorporating the full mechanisms of the pressure-sensitive yielding and the size dependence of plastic deformation still remains an open challenge. In this work, a mechanism-based stain gradient (MSG) plasticity theory for pressure sensitive materials with a variable material length-scale parameter is presented. The flow theory of MSG plasticity based on the Drucker–Prager yield function is established following the same hierarchical framework of MSG plasticity proposed by Gao et al., 1999, Huang et al., 2000 and Qiu et al. (2003) in order to link the strain gradient plasticity theory on the mesoscale to the Taylor dislocation model on the micro-scale. The incremental constitutive relation based on the associated flow rule is derived for the Drucker–Prager yield function on the micro-scale, including the higher-order stress introduced as the thermodynamic conjugate of strain gradient at the mesoscale. The proposed theory successfully predicts the experimental results. The numerical results show that when the pressure-sensitivity index defined by the Drucker–Prager yield function takes different values, the material response curves are different and the material strength increases with the increase of pressure-sensitivity index. It proves that this procedure is able to represent the material behavior of pressure-sensitive materials such as geomaterials, polymeric materials, metallic foams and metallic glass.     

Implicit frictional-contact model for soft particle systems

We introduce a novel numerical approach for the simulation of soft particles interacting via frictional contacts. This approach is based on an implicit formulation of the Material Point Method, allowing for large particle deformations, combined with the Contact Dynamics method for the treatment of unilateral frictional contacts between particles. This approach is both precise due to the treatment of contacts with no regularization and artificial damping parameters, and robust due to implicit time integration of both bulk degrees of freedom and relative contact velocities at the nodes representing the contact points. By construction, our algorithm is capable of handling arbitrary particle shapes and deformations. We illustrate this approach by two simple 2D examples: a Hertz contact and a rolling particle on an inclined plane. We also investigate the compaction of a packing of circular particles up to a solid fraction well above the jamming limit of hard particles. We find that, for the same level of deformation, the solid fraction in a packing of frictional particles is above that of a packing of frictionless particles as a result of larger particle shape change.     

A three-invariant cap model with isotropic–kinematic hardening rule and associated plasticity for granular materials

In this paper, a three-invariant cap model is developed for the isotropic–kinematic hardening and associated plasticity of granular materials. The model is based on the concepts of elasticity and plasticity theories together with an associated flow rule and a work hardening law for plastic deformations of granulars. The hardening rule is defined by its decomposition into the isotropic and kinematic material functions. The constitutive elasto-plastic matrix and its components are derived by using the definition of yield surface, material functions and non-linear elastic behavior, as function of hardening parameters. The model assessment and procedure for determination of material parameters are described. Finally, the applicability of proposed plasticity model is demonstrated in numerical simulation of several triaxial and confining pressure tests on different granular materials, including: wheat, rape, synthetic granulate and sand.     

一般各向异性单侧接触界面上波的反射和折射

研究简谐弹性波在一般各向异性介质单侧接触界面上的反射和折射问题．利用Fouier分析方法将非线性Coulomb摩擦接触边界波动问题化为一组代数方程．给出了确定局部分离、滑移和粘着区的思路和方法及各区域的解；讨论了出现界面局部分离和滑移的条件．对特定材料组合情况进行了详细数值计算，给出了界面力、相对滑移速度、张开位移、高频谐波的反射折射系数等特征参量；考察了平面和反平面波动的耦合及整体滑移等．其中关于高频谐波的结果可对已有实验结果给出很好的定性解释．在大多数情况下，即使对摩擦系数无穷大的粘滞接触界面，分离区端部也总是存在一个很小的滑移区。