2013 Koiter Medal Paper: Crack-Tip Fields and Toughness of Two-Dimensional Elasto-Plastic Lattices

The dependence of the fracture toughness of two dimensional elasto-plastic lattices upon relative density and ductility of cell wall material is obtained for four topologies: the triangular lattice, kagome lattice, diamond lattice, and the hexagonal lattice. Crack tip fields are explored, including the plastic zone size and crack opening displacement. The cell walls are treated as beams, with a material response given by the Ramberg-Osgood law. There is choice in the criterion for crack advance, and two extremes are considered: (i) the maximum local tensile strain anywhere in the lattice attains the failure strain, or (ii) the average tensile strain across the cell wall attains the failure strain (which can be identified with the necking strain). The dependence of macroscopic fracture toughness upon failure strain, strain hardening exponent and relative density are obtained for each lattice, and scaling laws are derived. The role of imperfections in degrading the fracture toughness is assessed by random movement of the nodes. The paper provides a strategy for obtaining lattices of high toughness at low density, thereby filling gaps in material property space

Creep failure of honeycombs made by rapid prototyping

Additive manufacture and rapid prototyping are versatile methods for the generation of lattice materials for applications in the creep regime. However, these techniques introduce defects that can degrade the macroscopic creep strength. In the present study, the uniaxial tensile response of two-dimensional PMMA lattices is measured in the visco-plastic regime: tests are performed at 100 °C which is slightly below the glass transition temperature Tg of PMMA. Both as-manufactured defects (Plateau borders and strut thickness variation) and as-designed defects (missing cell walls, solid inclusions, and randomly perturbed joints) are introduced. The dispersion in macroscopic strength is measured for relative densities in the range of 0.07–0.19. It is observed that initial failure of the lattice is diffuse in nature: struts fail at a number of uncorrelated locations, followed by the development of a single macroscopic crack transverse to the loading direction. In contrast, the same PMMA lattice fails in a correlated, brittle manner at room temperature. An FE study is performed to gain insight into the diffuse failure mode and the role played by as-manufactured defects, including the dispersion in tensile strength of individual struts of the lattice. A high damage tolerance to as-designed defects is observed experimentally: there is negligible knock-down in strength due to the removal of cell walls or to the presence of solid inclusions. These findings aid the design and manufacture of damage tolerant lattices in the creep regime.The authors gratefully acknowledge the financial support from the European Research Council (ERC) under the European Union’s Horizon 2020 research and innovation program, grant GA669764, MULTILAT

An assessment of the J-integral test for a metallic foam

An assessment is made of the J-integral test procedure for initial crack growth in an open-cell aluminium alloy foam by combining finite element (FE) simulations with experiment. It is found experimentally that a zone of randomly failed struts develops ahead of the primary crack tip, and is comparable in size to that of the plastic zone. Hence, a crack tip J-field is absent at the initiation of crack growth from the primary crack tip. This implies that the measured J_IC value and the J versus crack extension Da curve cannot be treated as material properties despite the fact that the specimen size meets the usual criteria for J validity. The toughness tests were performed on a single-edge notched bend specimen, and crack extension was measured by the direct current potential drop method, by digital image correlation and by X-ray computed tomography. The crack growth resistance of the foam is associated with two distinct zones of plastic dissipation: (i) a bulk plastic zone emanating from the crack tip (containing a cluster of randomly failed struts), and (ii) a crack bridging zone behind the advancing crack tip. The applicability of a cohesive zone model to predict the fracture response is explored for the observed case of large scale bridging. To do so, FE simulations are performed by replacing the discrete lattice of the open-cell metallic foam by a compressible, elastic-plastic hardening solid while the fracture process zone in the foam is represented by a cohesive zone, as characterised by a tensile traction versus separation law. A detailed comparison of the cohesive zone model with experimental observations reveals that it is possible to capture the load versus displacement response but not the details of the fracture process zone using a single set of process zone parameters

Indentation of a layer on foam substrate

There is a practical need to elevate both the indentation strength and level of energy absorption of engineering foams by the addition of a stiff and strong face sheet for applications such as packaging and crash mitigation. In this study, the enhancement in plane strain indentation resistance of a polyvinyl chloride (PVC) foam by the presence of a polycarbonate (PC) face sheet is determined by experiment, finite element analysis and by an analytical model. Plane strain indentation is by a flat-bottom punch or by a cylindrical roller, and the strain distribution within the PC face sheet and in the foam substrate are measured by digital image correlation. With increasing indent depth, the face sheet bends and stretches elastically and then plastically until face sheet or substrate fail. The generation of membrane tension in the face sheet plays a major role in supporting the indentation load when the indent depth exceeds the thickness of the face sheet, and leads to a strong hardening behaviour beyond the initial collapse load for indentation. Finite element predictions of the full indentation response are based upon the measured tensile and compressive responses of the PVC foam and PC layer. An analytical model is developed by matching the stretching response of the PC face sheet to the indentation response of the underlying foam, with due consideration for load diffusion from membrane tension of the PC face sheet into the underlying foam substrate. The indentation model is calibrated by ancillary finite element simulations of the load diffusion problem, and they emphasise the role of a shear lag zone in dictating the large indentation resistance. The indentation response of the bi-layer is also compared with that of a sandwich beam in 3-point bending. Experiments, finite element simulations and an additional analytical model for indentation of the sandwich beam in 3-point bending reveal that strong hardening of the post-yield load versus displacement response is now absent, in contrast to that of the bi-layer. The lack of hardening in 3-point bending is traced to the relatively low value of plastic bending moment of the beam section.We acknowledge financial support from the ERC MULTILAT, grant number 669764. This work was also supported by the Engineering and Physical Sciences Research Council, award number 1463953. The authors are grateful for the financial support from SABIC and the technical assistance from Dr. Martin van Es

The role of defects in dictating the strength of brittle honeycombs made by rapid prototyping

Rapid prototyping is an emerging technology for the fast make of engineering components. A common technique is to laser cut a two-dimensional (2D) part from polymethyl methacrylate (PMMA) sheet. However, both manufacturing defects and design defects (such as stress raisers) exist in the part, and these degrade its strength. In the present study, a combination of experiment and finite element analysis is used to determine the sensitivity of the tensile strength of PMMA hexagonal lattices to both as-manufactured and as-designed defects. The as-manufactured defects include variations in strut thickness and in Plateau border radius. The knockdown in lattice tensile strength is measured for lattice relative density in the range of 0.07 to 0.19. A systematic finite element (FE) study is performed to assess the explicit role of each type of as-manufactured defect on the lattice strength. As-designed defects such as randomly perturbed joints, missing cells, and solid inclusions are introduced within a regular hexagonal lattice. The notion of a transition flaw size is used to quantify the sensitivity of lattice strength to defect size.The authors gratefully acknowledge the financial support from the European Research Council under the European Union's Horizon 2020 research and innovation program, grant GA669764, MULTILAT

Notch sensitivity of orthotropic solids: interaction of tensile and shear damage zones

The macroscopic tensile strength of a panel containing a centre-crack or a centre-hole is predicted, assuming the simultaneous activation of multiple cohesive zones. The panel is made from an orthotropic elastic solid, and the stress raiser has both a tensile cohesive zone ahead of its tip, and shear cohesive zones in an orthogonal direction in order to represent two simultaneous damage mechanisms. These cohesive zones allow for two modes of fracture: (i) crack extension by penetration, and (ii) splitting in an orthogonal direction. The sensitivity of macroscopic tensile strength and failure mode to the degree of orthotropy is explored. The role of notch acuity and notch size are assessed by comparing the response of the pre-crack to that of the circular hole. This study reveals the role of the relative strength and relative toughness of competing damage modes in dictating the macroscopic strength of a notched panel made from an orthotropic elastic solid. Universal failure mechanism maps are constructed for the pre-crack and hole for a wide range of material orthotropies. The maps are useful for predicting whether failure is by penetration or kinking. Case studies are developed to compare the predictions with observations taken from the literature for selected orthotropic solids. It is found that synergistic strengthening occurs: when failure is by crack penetration ahead of the stress raiser, the presence of shear plastic zones leads to an enhancement of macroscopic strength. In contrast, when failure is by crack kinking, the presence of a tensile plastic zone ahead of the stress raiser has only a mild effect upon the macroscopic strength

The crack growth resistance of an elastoplastic lattice

The degree to which the toughness of a lattice material can be enhanced by the suitable placement of multiple phases is explored. To achieve this, the resistance to mode I and mode II crack growth in a two-dimensional (2D), elastoplastic, triangulated lattice is investigated using finite element (FE) simulations. The fully triangulated lattice is idealised as a pin-jointed truss, and each strut has an axial force versus elongation (or shortening) characteristic based on the uniaxial tensile response of an elastoplastic solid with power-law hardening. When the tensile force in the strut attains a critical value, a linear softening law is adopted for the force versus elongation response of the strut to simulate its failure. FE simulations of crack growth in the 2D lattice are performed under small-scale yielding conditions, and the sensitivity of the crack growth resistance curve (curve) to the cell wall strain hardening exponent and cell wall ductility is determined. Three concepts for enhancing the curve of a triangulated lattice are explored: (i) a brittle lattice reinforced by long ductile fibres transverse to the cracking plane, (ii) a bilattice such that a small scale brittle lattice is reinforced by a large scale ductile lattice, and (iii) a 2D version of an interpenetrating lattice wherein a large-scale ductile lattice is bonded at its joints to an underlying small-scale brittle lattice

The role of defects in dictating the strength of brittle honeycombs made by rapid prototyping

Rapid prototyping is an emerging technology for the fast make of engineering components. A common technique is to laser cut a two-dimensional (2D) part from polymethyl methacrylate (PMMA) sheet. However, both manufacturing defects and design defects (such as stress raisers) exist in the part, and these degrade its strength. In the present study, a combination of experiment and finite element analysis is used to determine the sensitivity of the tensile strength of PMMA hexagonal lattices to both as-manufactured and as-designed defects. The as-manufactured defects include variations in strut thickness and in Plateau border radius. The knockdown in lattice tensile strength is measured for lattice relative density in the range of 0.07 to 0.19. A systematic finite element (FE) study is performed to assess the explicit role of each type of as-manufactured defect on the lattice strength. As-designed defects such as randomly perturbed joints, missing cells, and solid inclusions are introduced within a regular hexagonal lattice. The notion of a transition flaw size is used to quantify the sensitivity of lattice strength to defect size

Crack kinking at the tip of a mode I crack in an orthotropic solid

The competition between crack penetration and crack kinking is addressed for a mode I macroscopic crack in an orthotropic elastic solid. Cohesive zones of finite peak strength and finite toughness are placed directly ahead of and orthogonal to the plane of the parent crack. The cohesive zone ahead of the crack tip is tensile in nature and leads to crack penetration, whereas the inclined zones slide without opening under a combined shear and normal traction, and give crack kinking. Thereby, the competition between continued crack growth by penetration ahead of the crack tip versus kinking is determined as a function of the relative strength and relative toughness of the cohesive zones. This competition is plotted in the form of a failure mechanism map, with the role of material orthotropy emphasized. Synergistic toughening is observed, whereby the parent crack tip is shielded by the activation of both the tensile and shear (kinking) cohesive zones, and the macroscopic toughness is elevated. The study is used to assess the degree to which various classes of composite have the tendency to undergo kinking