Search Results (314)

This study presents a comparative assessment of the Johnson–Cook (J-C) and Ductile Damage (DD) material models, evaluating their capability to replicate the tensile behavior and fracture development in ductile metals. Numerical models of AL6063-T4 aluminium and A36 steel dog-bone specimens with two different thicknesses were developed in ABAQUS to assess force–displacement response, stress–strain characteristics, and crack evolution under quasi-static loading. Results showed that specimen thickness directly doubled load capacity, while both models captured the overall elastic and plastic behavior of the materials. A key finding is that the DD model provided yield stresses closely matching the reference material values, whereas the J-C model exhibited higher apparent yields due to its intrinsic strain-rate sensitivity. Differences in damage behavior were also pronounced: the DD model better reproduced the gradual, inclined fracture path in aluminium, while the J-C model more accurately captured the strong necking-localization response characteristic of steel. Comparisons with experimentally tested specimens further supported these fracture tendencies. By analysing both materials under identical conditions, this work highlights the relative strengths and limitations of the two fracture formulations. The originality of the study lies in its systematic comparison across materials and thicknesses, providing clear guidance for selecting appropriate constitutive models in structural and computational mechanics research. Full article

Acrylonitrile Styrene Acrylate (ASA) is widely used in outdoor structural applications due to its favorable mechanical stability and weather resistance; however, its temperature-dependent plastic behavior remains insufficiently characterized for accurate numerical simulation. This study presents a non-standard method of calibrating the temperature-dependent Johnson–Cook (J-C) plasticity model for ASA in the practical operating temperature range below the glass transition temperature. Uniaxial tensile tests at constant strain rate 0.01 s⁻¹ were performed at −10 °C, +23 °C, and +65 °C to characterize the effect of temperature on the material’s plastic response. The J-C parameters $A$, $B$, and $n$ were identified for each temperature separately and globally using least-squares optimization implemented in MATLAB R2024b, showing good agreement with the experimental stress–strain curves. The calibrated parameters were subsequently implemented in Abaqus 2024 and validated through finite element simulations of the tensile tests. Numerical predictions demonstrated a very high correlation with the experimental data across all temperatures, confirming that the J-C model accurately captures the hardening behavior of ASA. The presented parameter set and calibration methodology provide a reliable basis for future simulation-driven design, forming analysis, and structural assessment of ASA components subjected to variable thermal conditions. Full article

This work presents a combined numerical and experimental investigation into the laser machining of aluminum alloy Al 1050 H14 using a high-power Continuous Wave (CW) fiber laser. Advanced three-dimensional, coupled thermal–structural Finite Element Method (FEM) simulations are developed to model key laser–material interaction processes, including laser-induced plastic deformation, laser etching, and engraving. Cases for both static single-shot and dynamic linear scanning laser beams are investigated. The developed numerical models incorporate a Gaussian heat source and the Johnson–Cook constitutive model to capture elastoplastic, damage, and thermal effects. The simulation results, which provide detailed insights into temperature gradients, displacement fields, and stress–strain evolution, are rigorously validated against experimental data. The experiments are conducted on an integrated setup comprising a 2 kW TRUMPF CW fiber laser hosted on a 3-axis CNC milling machine, with diagnostics including thermal imaging, thermocouples, white-light interferometry, and strain gauges. The strong agreement between simulations and measurements confirms the predictive capability of the developed FEM framework. Overall, this research establishes a reliable computational approach for optimizing laser parameters, such as power, dwell time, and scanning speed, to achieve precise control in metal surface treatment and modification applications. Full article

Inter-pass forging with different degrees of deformation during WAAM of Inconel 718 specimens (single-stage, three passes; two-stage, six passes) was investigated. Macrostructural analysis of the specimens showed that inter-pass forging led to a recrystallized structure. Alternation of layers with different grain shapes (columnar and equiaxed) is observed throughout the height of the specimens. Increasing the number of passes improves the mechanical properties of the material (tensile strength, yield strength, microhardness). A finite element model of inter-pass forging was developed to determine the effect of inter-pass surface deformation during WAAM on the residual stress–strain state. The non-stationary formulation was replaced with a quasi-static one. Johnson–Cook material constants were obtained for the deposited Inconel 718 material, including the effect of forging. Verification of the mathematical model was performed using a wall (specimen 2) deposited with single-stage forging. The deviation between the simulation results and the experiment did not exceed 15%. It was found that the sequence and number of passes significantly affect residual strain and displacements but have little effect on residual stress. Numerical modeling showed that the depth of plastic deformation exceeds the melting depth when depositing the subsequent layer, ensuring the preservation and accumulation of the inter-pass forging effect throughout the deposition process. Full article

This study presents a systematic numerical investigation into the ballistic performance of 7A52/7A62 aluminum alloy laminated plates with varying configurations. The dynamic mechanical behavior of the base alloys, 7A52 and 7A62, was first characterized experimentally, and the corresponding Johnson-Cook (J-C) constitutive parameters were calibrated. Using the calibrated J-C model, a series of numerical simulations were performed on several structural configurations, including single-layer (7A52-A, 7A62-B), double-layer (AB, BA), and four-layer laminates (ABAB, BAAB, ABBA, BABA). The results demonstrate that four-layer laminates exhibit markedly better ballistic performance than monolithic and double-layer plates. Among them, the ABAB stacking sequence—arranged in an alternating soft–hard–soft–hard pattern—shows the optimal performance, yielding a residual projectile velocity of only 256 m/s. This represents an approximately 27% reduction compared to the monolithic high-strength 7A62 plate. The overall ranking of ballistic performance is as follows: ABAB > BAAB > ABBA > BABA. Energy-based analysis further indicates that multi-interface delamination, coupled with plastic deformation and damage evolution, improves the energy-absorption efficiency of the laminated plates and thus enhances their ballistic resistance. This study offers valuable guidance for the lightweight design of laminated 7XXX-series aluminum alloy protective plates. Full article

The present work develops an explicit dynamic finite element model of soil–disc interaction for a notched harrow disc, aiming to quantify how APS coatings, soil type and disc–soil friction influence stresses in the disc and surrounding soil. The model reproduces a four-gang offset harrow operating at 7 km/h, 0.15 m working depth, with 18°disc angle and 15° tilt angle, and compares an uncoated steel disc with three APS-coated variants (P1 Metco 71NS, P2 Metco 136F, P3 Metco 45C-NS). Mechanical properties of the substrate and coatings are obtained from micro-indentation tests and introduced via a bilinear steel model and Johnson–Cook plasticity for the coatings, while disc–soil friction coefficients are calibrated from microscratch measurements. Soil behaviour is described using the AUTODYN Granular model for four representative agricultural soils, spanning sandy loam to saturated heavy clay. Results show that the uncoated disc develops von Mises stresses in the disc–soil contact region of ≈150–220 MPa, with intermediate-stiffness soils being most critical. APS coatings significantly alter both the level and distribution of stresses: P2, the stiffest ceramic, yields the highest stresses (≈421–448 MPa), P1 keeps stresses near the baseline while shielding the substrate through extended plastic zones, and P3 provides an intermediate, more uniformly distributed stress regime. Increasing disc–soil friction systematically amplifies von Mises stresses in the contact region, especially for P2. Overall, the calibrated explicit model captures the coupled influence of soil properties, coating stiffness and friction, and indicates that P1 is better suited for light-to-medium soils, P3 offers the most balanced response in medium-to-stiff soils, whereas P2 should be reserved for highly abrasive conditions and used with caution in cohesive soils. Full article

The present work studies the developing network of adiabatic shear bands (ASBs) during dynamic plane strain compression of orthogonal AISI 1045 steel billets, aiming to investigate the ASB trajectories and their evolution mechanism. This paper conducts a finite element (FE) numerical analysis in LS-DYNA software, developing a doubly coupled analysis by combining both structural–thermal and structural–damage couplings. The Modified Johnson–Cook (MJC) formulas are considered for modeling both the material plasticity and damage law, implementing thermo-viscoplastic numerical approaches, while a critical temperature for material failure is further adjusted. Finally, the case study relates to a parametric analysis of specimen aspect ratio, aiming to reveal its effect on the developing ASB network and its propagating characteristics. Full article

Adhesively bonded joints are extensively utilized in structural assemblies involving metals, composites, and hybrid materials due to their favorable mechanical and manufacturing characteristics. However, their performance under high-velocity impacts—common in aerospace, automotive, and defense applications—remains insufficiently understood. This work investigates the high-velocity performance and subsequent tensile response of adhesively bonded single-lap joints (SLJs) by integrating experimental testing with numerical simulations. High-velocity impacts were applied to SLJs fabricated from 4 mm aluminum adherends with overlap lengths of 15 mm and 25 mm, using a 1.25 g projectile at 288 m/s, followed by quasi-static tensile assessment. Experimental findings revealed substantial degradation in tensile strength for the 15 mm overlap configuration (reduced the load-bearing capacity by about 33% (from ~12 kN to ~8 kN)), while the 25 mm overlap retained its structural integrity. Finite element simulations conducted in ABAQUS 2021 employed the Johnson–Cook constitutive model for the adherends and a cohesive zone model for the adhesive layer, successfully replicating damage evolution and stress distributions. The results highlight the critical role of geometric parameters—particularly overlap length and adherend thickness—in determining the damage tolerance and residual load-bearing capacity of SLJs subjected to high-velocity impacts. These insights contribute to the development of more robust bonded joint designs for impact-prone environments. Full article

With the growing requirements for multi-particle process simulation, improving computational accuracy, efficiency, and scalability has become a critical challenge. This study generally focused on comprehensive analyses of existing numerical methods for simulating particle–substrate interactions in gas–thermal spraying (including gas–dynamic spraying processes), covering both single-particle and multi-particle models to develop practical recommendations for the optimization of modern coating spraying processes. First of all, this paper systematically analyzes the key limitations of current approaches, including their inability to handle high deformations effectively or high computational complexity and their insufficient accuracy in dynamic scenarios. A comparative evaluation of four numerical methods (Lagrangian, Arbitrary Lagrangian–Eulerian (ALE), Coupled Eulerian–Lagrangian (CEL), and Smoothed Particle Hydrodynamics (SPH)) revealed their strengths and weaknesses in modeling of real gas–thermal spraying processes. Furthermore, this study identifies the limitations of the widely used Johnson–Cook (JC) constitutive model under extreme conditions. The authors considered the Zerilli–Armstrong (ZA), Mechanical Threshold Stress (MTS), and Preston–Tonks–Wallace (PTW) models as more realistic alternatives to the Jonson–Cook model. Finally, comparative analyses of theoretical and realistic deformation and defect-generation processes in gas–thermal coatings emphasize the critical need for fundamental changes in the simulation strategy for modern gas–thermal spraying processes. Full article

A Machine Learning (ML)-based surrogate modeling framework is presented for mapping structure–property relationships in architected Ti6Al4V cylindrical TPMS metamaterials subjected to quasi-static compression. A Python–nTop pipeline automatically generated 3456 cylindrical shell lattices (Gyroid, Diamond, Split-P), and ABAQUS/Explicit simulations with a Johnson–Cook failure model for Ti6Al4V quantified their mechanical response. From 3024 valid designs, key mechanical properties targets including elastic modulus (E), yield stress (Y), ultimate strength (U), plateau stress (PL), and energy absorption (EA) were extracted alongside geometric descriptors such as surface area (SA), surface-area-to-volume ratio (SA/VR), and relative density (RD). A multi-output surrogate model (feedforward neural network) trained on the simulated set accurately predicts these properties directly from seven design parameters (thickness; unit cell counts in X, Y, and Z directions; unit cell orientation; height; diameter), enabling rapid property estimation across large design spaces. Topology-dependent trends indicate that Split-P exhibits the highest strength, energy absorption, and total SA, and shows the largest variation in SA/VR; Gyroid exhibits the lowest SA with a moderate SA/VR; and Diamond is the most compliant lattice and maintains a higher SA/VR than Gyroid despite lower SA. RD increases with both SA and SA/VR across all topologies. The framework provides a reusable computational tool for architectured lattices, enabling quick prescreening of implant designs without repeated finite-element analyses. Full article

L360QS pipeline steel, due to its high toughness, high strength, resistance to sulfide stress cracking, and resistance to hydrogen-induced cracking, is increasingly being used in pipeline network construction. Its fracture behavior is a critical factor for safe operation in mountainous steep-slope environments, but it has not yet been widely studied. Therefore, this paper conducts extensive experiments on the ductile fracture of L360QS pipeline steel. The tests employed standard tensile, notched tensile, shear, and compression specimens, covering a stress triaxiality range from approximately −0.33 to 0.92. The study combined Ling’s iterative method to establish an elastoplastic constitutive model considering post-necking behavior, and incorporated it into finite element models to extract the average stress triaxiality and equivalent plastic strain at the moment of fracture initiation for each type of specimen. Based on the extracted data, a piecewise ductile fracture model was established: a simplified Johnson–Cook criterion is used in the high triaxiality range, while an empirical function is used to describe fracture behavior in the medium, low, and negative triaxiality ranges. The model was validated using a train–test split approach, predicting fracture displacements for an independent test set of specimens. The results showed all prediction errors were within 5%, demonstrating the model’s high accuracy. Furthermore, a Spearman correlation analysis quantified the influence of geometric factors, revealing that notch curvature has the strongest monotonic relationship in controlling average stress triaxiality and fracture strain. The fracture model established in this paper can accurately predict the fracture behavior of L360QS pipeline steel and provides a reliable basis for failure prediction and safety assessment under complex service conditions (such as mountainous steep slopes). Full article

The accurate modelling of material removal mechanisms in grinding processes requires precise constitutive equations describing dynamic material behaviour under extreme strain rates and large deformations. This study presents a novel methodology for optimising the Johnson–Cook (J–C) constitutive model parameters for micro-grinding applications, addressing the limitations of conventional mechanical testing at strain rates exceeding 10⁵ s⁻¹. The research employed single abrasive grain micro-cutting experiments using a diamond Vickers indenter on aluminium alloy 7075-T6 specimens. High-resolution topographic measurements (130 nm lateral resolution) were used to analyse the scratch geometry and lateral material displacement patterns. Ten modified J–C model variants (A1–A10) were systematically evaluated through finite element simulations, focusing on parameters governing plastic strengthening (B, n) and strain rate sensitivity (C). Quantitative non-conformity criteria assessed agreement between experimental and simulated results for cross-sectional areas and geometric shapes of material pile-ups and grooves. These criteria enable an objective evaluation by comparing the pile-up height (h), width (l), and horizontal distance to the peak (d). The results demonstrate that conventional J–C parameters from Hopkinson bar testing exhibit significant discrepancies in grinding conditions, with unrealistic stress values (17,000 MPa). The optimised model A3 (A = 473 MPa, B = 80 MPa, n = 0.5, C = 0.001) achieved superior convergence, reducing the non-conformity criteria to Σk_A = 0.46 and Σk_K = 1.16, compared to 0.88 and 1.67 for the baseline model. Strain mapping revealed deformation values from ε = 0.8 to ε = 11 in lateral pile-up regions, confirming the necessity of constitutive models describing material behaviour across wide strain ranges. The methodology successfully identified optimal parameter combinations, with convergence errors of 1–14% and 7–60% on the left and right scratch sides, respectively. The approach provides a cost-effective alternative to expensive dynamic testing methods, with applicability extending to other ductile materials in precision manufacturing. Full article

A touch-off explosion on concrete slabs is considered one of the simplest yet most destructive forms of adversarial loading on building elements. It causes far greater damage than explosions occurring at a distance. The impact is usually concentrated in a small area, leading to surface cratering, scabbing of concrete, and even tearing or rupture of the reinforcement. Studies available on the behavior of reinforced concrete (RC) slabs under touch-off (contact) and standoff explosions commonly indicate that the maximum damage occurs when the blast is applied to the center of the slab. This observation raises an important question about how the position of an explosive charge, especially relative to the free edge of the slab, affects the overall damage pattern in slabs supported on only two sides with clamped supports. This study uses a modeling strategy combining Eulerian and Lagrangian domains using the finite element tools of Abaqus Explicit v2020 to examine the behavior of a square slab supported on two sides with clamped ends subjected to blast loads at different positions, ranging from the center to the free edge and beyond, under touch-off explosion conditions. The behavior of concrete was captured using the Concrete Damage Plasticity model, while the reinforcement was represented with the Johnson–Cook model. Effects of strain rate were included by applying calibrated dynamic increase factors. The developed numerical model is validated first with experimental data available in the published literature for the case where the explosive charge is positioned at the slab’s center, showing a very close agreement with the reported results. Along with the central blast position, five additional cases were considered for further investigation as they have not been investigated in the existing literature and were found to be worthy of study. The selected locations of the explosive charge included an intermediate zone (between the slab center and free edge), an in-slab region (partly embedded at the free edge), a partial edge (partially outside the slab), an external edge (fully outside the free edge), and an offset position (250 mm beyond the free edge along the central axis). Results indicated a noticeable transition in damage patterns as the detonation point shifted from the slab’s center toward and beyond the free edge. The failure mode changed from a balanced perforation under confined conditions to an asymmetric response near the free edge, dominated by weaker surface coupling but more pronounced tensile cracking and bottom-face perforation. The reinforcement experienced significantly varying tensile and compressive stresses depending on blast position, with the highest tensile demand occurring near free-edge detonations due to intensified local bending and uneven shock reflection. Full article

The paper presents the results of numerical simulation of the dynamic behaviour of the post-tensioned beams subjected to a constant force impulse load over time and a short-term force impulse load varying over time. Abaqus programme was used for numerical analysis, introducing necessary and detailed modifications to the modelling and calibration parameters. The numerical dynamics models were calibrated using results previously obtained from our own experimental and numerical static analysis. To estimate the dynamic strength of structural materials, the dynamic strength coefficient was applied in the concrete damage plasticity model, and the Johnson–Cook model was used to describe the evolution of the dynamic yield strength of steel elements. An explicit procedure was used to solve the dynamic equilibrium equations. The selection of the Rayleigh damping parameter and the methodology for determining the external load in a dynamic problem are discussed. The study presents new results on the influence of the type of force impulse loading and variable prestressing eccentricity in numerical simulations of post-tensioned beams. The results of the simulation show that the post-tensioned beams achieved a lower dynamic load capacity under a constant force impulse load of approximately 5% compared to the static load capacity achieved in the experimental static tests, regardless of the assumed prestressing eccentricity. A dynamic load capacity significantly exceeded the static load capacity under short-term time-varying force impulse loading. The beam with the larger prestressing eccentricity achieved a dynamic load capacity of 211% of the static load capacity, while the beam with the smaller prestressing eccentricity achieved a dynamic load capacity of 198% of the static load capacity. Full article

Carbon-Fiber-Reinforced Plastic (CFRP) is a typical lightweight material used in the aerospace industry. However, the automotive industry has focused on the application of composite materials in vehicle components for weight reduction. In particular, hybrid parts consisting of CFRP reinforcement and a steel outer have been investigated in many studies as a solution to satisfy weight reduction and high strength. In this paper, a steel/CFRP hybrid part was evaluated by impact analysis using several material models, such as the Johnson–Cook model, progressive damage analysis (PDA), and cohesive zone model (CZM). First, the mechanical properties of the steel were determined under different strain rates to assess collision effects. Subsequently, the material properties of the CFRP were evaluated to predict the failure of composite material in the tensile and compressive directions. In addition, the cohesive properties of adhesive film were evaluated under normal and shear modes. Finally, impact analysis using the obtained material properties was conducted to predict the behavior and strength of the steel/CFRP hybrid part under collisions, and the results were compared with the experimental results for verification. Full article