Validation of thermal-mechanical modeling of stainless steel forgings

A constitutive model for recrystallization has been developed within the framework of an existing dislocation-based rate and temperature-dependent plasticity model. The theory has been implemented and tested in a finite element code. Material parameters were fit to data from monotonic compression tests on 304L steel for a wide range of temperatures and strain rates. The model is then validated by using the same parameter set in predictive thermal-mechanical simulations of experiments in which wedge forgings were produced at elevated temperatures. Model predictions of the final yield strengths compare well to the experimental results

A mechanism-based approach to modeling ductile fracture.

Ductile fracture in metals has been observed to result from the nucleation, growth, and coalescence of voids. The evolution of this damage is inherently history dependent, affected by how time-varying stresses drive the formation of defect structures in the material. At some critically damaged state, the softening response of the material leads to strain localization across a surface that, under continued loading, becomes the faces of a crack in the material. Modeling localization of strain requires introduction of a length scale to make the energy dissipated in the localized zone well-defined. In this work, a cohesive zone approach is used to describe the post-bifurcation evolution of material within the localized zone. The relations are developed within a thermodynamically consistent framework that incorporates temperature and rate-dependent evolution relationships motivated by dislocation mechanics. As such, we do not prescribe the evolution of tractions with opening displacements across the localized zone a priori. The evolution of tractions is itself an outcome of the solution of particular, initial boundary value problems. The stress and internal state of the material at the point of bifurcation provides the initial conditions for the subsequent evolution of the cohesive zone. The models we develop are motivated by in-situ scanning electron microscopy of three-point bending experiments using 6061-T6 aluminum and 304L stainless steel, The in situ observations of the initiation and evolution of fracture zones reveal the scale over which the failure mechanisms act. In addition, these observations are essential for motivating the micromechanically-based models of the decohesion process that incorporate the effects of loading mode mixity, temperature, and loading rate. The response of these new cohesive zone relations is demonstrated by modeling the three-point bending configuration used for the experiments. In addition, we survey other methods with the potential to provide more detailed information about the near tip deformation fields

A robust, coupled approach for atomistic-continuum simulation.

This report is a collection of documents written by the group members of the Engineering Sciences Research Foundation (ESRF), Laboratory Directed Research and Development (LDRD) project titled 'A Robust, Coupled Approach to Atomistic-Continuum Simulation'. Presented in this document is the development of a formulation for performing quasistatic, coupled, atomistic-continuum simulation that includes cross terms in the equilibrium equations that arise due to kinematic coupling and corrections used for the calculation of system potential energy to account for continuum elements that overlap regions containing atomic bonds, evaluations of thermo-mechanical continuum quantities calculated within atomistic simulations including measures of stress, temperature and heat flux, calculation used to determine the appropriate spatial and time averaging necessary to enable these atomistically-defined expressions to have the same physical meaning as their continuum counterparts, and a formulation to quantify a continuum 'temperature field', the first step towards constructing a coupled atomistic-continuum approach capable of finite temperature and dynamic analyses

Modeling of friction-induced deformation and microstructures.

Frictional contact results in surface and subsurface damage that could influence the performance, aging, and reliability of moving mechanical assemblies. Changes in surface roughness, hardness, grain size and texture often occur during the initial run-in period, resulting in the evolution of subsurface layers with characteristic microstructural features that are different from those of the bulk. The objective of this LDRD funded research was to model friction-induced microstructures. In order to accomplish this objective, novel experimental techniques were developed to make friction measurements on single crystal surfaces along specific crystallographic surfaces. Focused ion beam techniques were used to prepare cross-sections of wear scars, and electron backscattered diffraction (EBSD) and TEM to understand the deformation, orientation changes, and recrystallization that are associated with sliding wear. The extent of subsurface deformation and the coefficient of friction were strongly dependent on the crystal orientation. These experimental observations and insights were used to develop and validate phenomenological models. A phenomenological model was developed to elucidate the relationships between deformation, microstructure formation, and friction during wear. The contact mechanics problem was described by well-known mathematical solutions for the stresses during sliding friction. Crystal plasticity theory was used to describe the evolution of dislocation content in the worn material, which in turn provided an estimate of the characteristic microstructural feature size as a function of the imposed strain. An analysis of grain boundary sliding in ultra-fine-grained material provided a mechanism for lubrication, and model predictions of the contribution of grain boundary sliding (relative to plastic deformation) to lubrication were in good qualitative agreement with experimental evidence. A nanomechanics-based approach has been developed for characterizing the mechanical response of wear surfaces. Coatings are often required to mitigate friction and wear. Amongst other factors, plastic deformation of the substrate determines the coating-substrate interface reliability. Finite element modeling has been applied to predict the plastic deformation for the specific case of diamond-like carbon (DLC) coated Ni alloy substrates

Formulation and validation of a thermomechanical viscoplastic constitutive model for amorphous glassy polymer

International audiencePolymers exhibit a rich variety of mechanical behaviour originating from their particular microstructure. To capture such intricate structure properties, a number of polymer constitutive models have been proposed and implemented into finite element codes in an effort to solve complex engineering problems. However, developing improved constitutive models for polymers that are physically-based has proven to be a challenging area with important implications for the design of polymeric structural components

Modeling the Dynamic Failure of Railroad Tank Cars Using a Physically Motivated Internal State Variable Plasticity/Damage Nonlocal Model

We used a physically motivated internal state variable plasticity/damage model containing a mathematical length scale to idealize the material response in finite element simulations of a large-scale boundary value problem. The problem consists of a moving striker colliding against a stationary hazmat tank car. The motivations are (1) to reproduce with high fidelity finite deformation and temperature histories, damage, and high rate phenomena that may arise during the impact accident and (2) to address the material postbifurcation regime pathological mesh size issues. We introduce the mathematical length scale in the model by adopting a nonlocal evolution equation for the damage, as suggested by Pijaudier-Cabot and Bazant in the context of concrete. We implement this evolution equation into existing finite element subroutines of the plasticity/failure model. The results of the simulations, carried out with the aid of Abaqus/Explicit finite element code, show that the material model, accounting for temperature histories and nonlocal damage effects, satisfactorily predicts the damage progression during the tank car impact accident and significantly reduces the pathological mesh size effects

A general inelastic internal state variable model for amorphous glassy polymers

International audienceThis paper presents the formulation of a constitutive model for amorphous thermoplastics using a thermodynamic approach with physically motivated internal state variables. The formulation follows current internal state variable methodologies used for metals and departs from the spring-dashpot representation generally used to characterize the mechanical behavior of polymers like those used by Ames et al. in Int J Plast, 25, 1495–1539 (2009) and Anand and Gurtin in Int J Solids Struct, 40, 1465–1487 (2003), Anand and Ames in Int J Plast, 22, 1123–1170 (2006), Anand et al. in Int J Plast, 25, 1474–1494 (2009). The selection of internal state variables was guided by a hierarchical multiscale modeling approach that bridged deformation mechanisms from the molecular dynamics scale (coarse grain model) to the continuum level. The model equations were developed within a large deformation kinematics and thermodynamics framework where the hardening behavior at large strains was captured using a kinematic-type hardening variable with two possible evolution laws: a current method based on hyperelasticity theory and an alternate method whereby kinematic hardening depends on chain stretching and material plastic flow. The three-dimensional equations were then reduced to the one-dimensional case to quantify the material parameters from monotonic compression test data at different applied strain rates. To illustrate the generalized nature of the constitutive model, material parameters were determined for four different amorphous polymers: polycarbonate, poly(methylmethacrylate), polystyrene, and poly(2,6-dimethyl-1,4-phenylene oxide). This model captures the complex character of the stress–strain behavior of these amorphous polymers for a range of strain rates

Progress report for the ASCI AD resistance weld process modeling project AD2003-15.

This report documents activities related to the ASCI AD Resistance Weld Process Modeling Project AD2003-15. Activities up to and including FY2004 are discussed. This was the third year for this multi year project, the objective of which is to position the SIERRA computational tools for the solution of resistance welding problems. The process of interest is a three-way coupled problem involving current flow, temperature buildup and large plastic deformation. The DSW application is the reclamation stem weld used in the manufacture of high pressure gas bottles. This is the first year the CALAGIO suite of codes (eCALORE, CALORE, and ADAGIO) was used to successfully solve a three-way coupled problem in SIERRA. This report discusses the application of CALAGIO to the tapered bar acceptance problem and a similar but independent tapered bar simulation of a companion C6 experiment. New additions to the EMMI constitutive model and issues related to CALAGIO performance are also discussed