Search Results (109)

The patch loading resistance of slender steel plate girders is a critical factor in the design of launched steel and composite steel–concrete bridges. Traditional design methods enhance patch loading resistance through various stiffening techniques, with contributions typically estimated via code expressions calibrated on experimental data that do not always reflect the complexities of full-scale bridge applications. Finite Element (FE) modeling offers a more realistic alternative, though its practical application is often hindered by modeling uncertainties and nonlinearities. To bridge this gap, this paper introduces an advanced FE modeling approach. It provides a comprehensive description of an FE model that accurately predicts both the load–displacement behavior and the patch loading resistance. The model is benchmarked against a broad set of experimental tests and systematically investigates the effects of key modeling parameters and their interactions—material stress–strain law, boundary condition representation, stiffness of the load introduction area, initial geometric imperfections, and solving algorithms. Key findings demonstrate that a bilinear elastoplastic material model with hardening is sufficient for estimating ultimate resistance, and kinematic constraints can effectively replace rigid transverse stiffeners. The stiffness of the load application zone significantly influences the response, especially in launched bridge scenarios. Initial imperfections notably affect both stiffness and strength, with standard fabrication tolerances offering suitable input values. The modified Riks algorithm is recommended for its efficiency and stability in nonlinear regimens. The proposed methodology advances the state of practice by providing a simple yet reliable FE modeling approach for predicting patch loading resistance in real-world bridge applications, leading to safer and more reliable structural designs. Full article

Pile foundations are commonly used to support structures subjected to complex loading conditions. In seismic-prone regions, understanding the soil–pile interaction under cyclic loading is essential for ensuring the stability and safety of these foundations. Numerical modeling is an effective tool for predicting the nonlinear behavior of soil under seismic excitation, but selecting an appropriate constitutive model remains a significant challenge. This study investigates the seismic behavior of pile groups embedded in soft clay using advanced finite element analysis. The piles are modeled as aluminum with a linear elastic response and are analyzed within a soil domain characterized by two kinematic hardening constitutive models based on the Von Mises failure criterion. Model parameters are calibrated using a combination of experimental and numerical data. The study also examines the influence of pile spacing within the group on seismic response, revealing notable differences in the response patterns. The results show that the nonlinear kinematic hardening model provides a more accurate correlation with experimental centrifuge test results compared to the multilinear model. These findings contribute to enhancing the understanding of soil–pile interaction under seismic loading and improving the design of pile foundations. Full article

The main dimensional errors in stamped parts are caused by the springback phenomenon. Those errors usually lead to assembly difficulties and/or the malfunction of those parts. The objective of this contribution is to give a comprehensive and detailed view of the sheet metal-forming process of an actual industrial part, with the focus on the setup adjustment of the blank-holder force (BHF), using the springback as the determining factor of the manufacturing quality. The complete cycle of the simulation will be detailed from the experimental determination of the model parameters to the correlation with experimental results of the simulated values. Many studies use simple geometries with limited practical application, failing to provide a quantitative understanding of actual springback in industrial processes. This work aims to offer a realistic reference for springback in a real production part, combining numerical prediction during design using a well-established model and experimental measurements in the factory. The simulation, carried out using LS-DYNA, determines the influence of the BHF in the springback observed in the manufacturing process of a gas cooktop part made from non-stable austenitic 1.4301 steel. The material has been modeled using Barlat’s Yld2000, experimentally determining the strain rate-dependent hardening, yield locus and isotropic–kinematic hardening. To validate the model, an experimental campaign has been developed, testing the part with values of BHF within the range of 50 t to 200 t. The results show that the numerical model is able to represent the influence of the BHF on the springback, demonstrating the relation between them. Full article

Steel structures subjected to earthquakes or extreme cyclic loadings may undergo extensive damage and fractures due to ultra-low-cycle fatigue (ULCF). Although assessments of damage initiation and evolution parameters have been carried out for some steels exposed to low-cycle fatigue, so far, these parameters for structural steels exposed to ULCF have neither been sufficiently studied nor quantified. Accordingly, this paper provides the results of finite element analysis (FEA) concerning the ULCF behaviors of S355 and S690 steel specimens. Calibration of the damage parameters is performed in SIMULIA Abaqus 6.11 FEA software using a direct cyclic algorithm and available experimental data. Kliman’s model for the hysteresis energy of cyclic loading is used to analytically verify the damage parameters. In addition, available experimental data were obtained from cyclic axial strain tests on S355 and S690 steel specimens according to the ASTM International standard E606/E606M-21. Finally, the non-linear Chaboche–Lemaitre (C–L) combined isotropic–kinematic hardening model is used for the characterization of the ULCF behavior of S355 steel in a simple cylindrical bar. It is found that the two damage initiation parameters are 5.0 and −0.8, the first damage initiation parameter is dominant when modeling the number of cycles to failure, and the second damage initiation parameter is a material constant. Full article

Parabolic leaf springs are components typically found in suspensions of freight railway rolling stock. These components are produced in high-strength alloyed steel, DIN 51CrV4, to resist severe loading and environmental conditions. Despite the material’s good mechanical characteristics, the geometric notches and high surface roughness that features its leaves might raise local stress levels to values above the elastic limit, with cyclic elasto-plastic behaviour models being more appropriate. In this investigation, the parameters of the Chaboche model combining the kinematic and isotropic hardening models are determined using experimental data previously obtained in strain-controlled cyclic tests. Once the parameters of the cyclic hardening model are determined, they are validated using a finite element approach considering the Chaboche cyclic plasticity model. As a result, the material properties specified in this investigation can be used in the fatigue mechanical design of parabolic leaf springs made with 51CrV4 (local approaches to notches and at surface roughness level) or even in other components produced with the same steel. Full article

The concept of rocking foundations has been successfully tested and promoted for building and bridge foundations. In this paper, the applicability of rocking foundations to wind turbines is investigated, specifically for wind turbines constructed on undrained clay. An efficient form of von Mises constitutive model with non-linear kinematic hardening is integrated with the ABAQUS finite element software by a computer code and validated against experimental data. A cohesive contact of foundation–soil with limited tension is applied to simulate suction stresses at the foundation bottom–soil interface, which better represented the rocking foundation behavior. The obtained finite element results demonstrate that by allowing minimal foundation uplift under operational loads, an existing foundation can be used to support loads from a larger wind turbine than it is designed for. Allowing such uplifts corresponds to a rocking foundation design that is demonstrated in this paper to be safe and functional for a wind turbine under both operational and extreme conditions. Full article

High-strength steels such as Dual Phase (DP), Transformation-Induced Plasticity (TRIP), and Twinning-Induced Plasticity (TWIP) steels have gained importance in automotive applications due to the potential for weight reduction and increased performance in crash tests. However, as resistance increases, there is also an increase in springback due to residual stresses after the forming process. This is mainly because of the greater elastic region of these materials and other factors associated with strain hardening, such as the Bauschinger effect, that brings theory of kinematic hardening to mathematical modeling. This means that finite element software must consider these properties so that the simulation can accurately predict the behavior. Currently, this knowledge is still not widespread since it has never been used in conventional materials. Additionally, engineers and researchers use the Forming Limit Diagram (FLD) curve in their studies. However, it does not fully represent the actual failure limit of materials, especially in high-strength materials. Based on this, the Fracture Forming Limit Diagram (FFLD) curve has emerged, which proposes to resolve these limitations. Thus, this review aims to focus on how finite element methods consider all these factors in their modeling, especially when it comes to the responses of high-strength steels. Full article

This paper presents micromechanical analyses of an orthogonally reinforced composite with new constitutive equations of kinematic plastic hardening. The homogenization of plastic properties was performed through a numerical analysis of a representative volume using the finite element method. A modification of Prager’s theory was used to construct physical relations for an equivalent orthotropic material. In the proposed version of the theory, a special tensor for back stresses is introduced, which takes into account the difference in the rate of hardening for different types of plastic deformation. For boron–aluminum orthogonally reinforced composite with known mechanical properties of fibers and matrix, all material parameters of the theory were determined, deformation diagrams were constructed, and the equation for a plasticity surface in a six-dimensional stress space was obtained. The advantage of the developed method of numerical homogenization is that it only requires a minimal amount of experimental data. The efficiency of micromechanical analysis makes it possible to optimally design metal matrix composites with the required plastic properties. Full article

This paper investigates the seismic performance of thin-walled stiffened steel square box columns, modeling bridge piers subjected to unidirectional cyclic lateral loading with a constant axial load, focusing on local, global, and local-global interactive buckling phenomena. Initially, the finite element model was validated against existing experimental results. The study further explored the degradation in strength and ductility of both thin-walled and compact columns under cyclic loading. Thin-walled, stiffened steel square box columns exhibited buckling near the base, forming a half-sine wave shape. The research also addresses discrepancies from different material models used to analyze steel tubular bridge piers. Analysis using a modified two-surface plasticity model (2SM) yielded results closer to experimental data than a multi-linear kinematic hardening model, particularly for compact sections. The 2SM, which accounts for cycling within the yield plateau and strain hardening regime, demonstrated enhanced accuracy over the multi-linear kinematic hardening model. Additionally, a parametric study was conducted to assess the impact of key design parameters—such as width-to-thickness ratio (R_f), column slenderness ratio (λ), and magnitude of axial load (P/P_y)—on the performance of thin-walled stiffened steel square box columns. Design equations were then developed to predict the strength and ductility of bridge piers. These equations closely matched experimental results, achieving an accuracy of 95% for ultimate strength and 97% for ductility. Full article

Magnesium alloys, particularly AZ31, are promising materials for the modern automotive industry, offering significant weight savings and environmental benefits. This research focuses on the challenges associated with accurate modelling of multiaxial cyclic plasticity at small strains of AZ31 under low-cycle fatigue conditions. Current modelling approaches, including crystal plasticity and phenomenological plasticity, have been extensively explored. However, the existing models reach their limits when it comes to capturing the complexity of cyclic plasticity in magnesium alloys, especially under multiaxial loading conditions. To address this gap, a cyclically stable elastoplastic model is proposed that integrates elements from existing models with an enhanced algorithm for updating stresses and hardening parameters, using the hyperbolic tangent function to describe hardening and ensure a stabilised response with closed hysteresis loops for both uniaxial and multiaxial loading. The model is based on a von Mises yield surface and includes a kinematic hardening rule that promises a stable simulation of the response of AZ31 sheets under cyclic loading. Using experimental data from previous studies on AZ31 sheets, the proposed model is optimised and validated. The model shows promising capabilities in simulating the response of AZ31 sheet metal under different loading conditions. It has significant potential to improve the accuracy of fatigue simulations, especially in the context of automotive applications. Full article

Modern mechanical engineering faces high competition in global markets, which requires manufacturers of process equipment to significantly reduce production costs while ensuring high product quality and maximum productivity. Metalworking occupies a significant part of industrial production and consumes a significant share of the world’s energy and natural resources. Improving the technology of manufacturing parts with an emphasis on more efficient use of metalworking machines is necessary to maintain the competitiveness of the domestic machine tool industry. Hybrid metalworking systems based on the principles of multi-purpose integration eliminate the disadvantages of monotechnologies and increase efficiency by reducing time losses and intermediate operations. The purpose of this work is to develop and implement a hybrid machine tool system and an appropriate combined technology for manufacturing machine parts. Theory and methods. Studies of the possible structural composition and layout of hybrid equipment at integration of mechanical and surface-thermal processes were carried out, taking into account the basic provisions of structural synthesis and componentization of metalworking systems. Theoretical studies were carried out using the basic provisions of system analysis, geometric theory of surface formation, design of metalworking machines, methods of finite elements, and mathematical and computer modeling. The mathematical modeling of thermal fields and structural-phase transformations during HEH HFC was carried out in ANSYS (version 19.1) and SYSWELD (version 2010) software packages using numerical methods of solving differential equations of unsteady heat conduction (Fourier equation), carbon diffusion (2nd Fick’s law) and elastic–plastic behavior of the material. The verification of the modeling results was carried out using in situ experiments employing the following: optical and scanning microscopy; and mechanical and X-ray methods of residual stress determination. Formtracer SV-C4500 profilograph profilometer was used in the study for simultaneous measurement of shape deviations and surface roughness. Surface topography was assessed using a Walter UHL VMM 150 V instrumental microscope. The microhardness of the hardened surface layer of the parts was evaluated on a Wolpert Group 402MVD. Results and discussion. The original methodology of structural and kinematic analysis for pre-design studies of hybrid metalworking equipment is presented. Methodological recommendations for the modernization of multi-purpose metal-cutting machine tool are developed, the implementation of which will make it possible to implement high-energy heating with high-frequency currents (HEH HFC) on a standard machine tool system and provide the formation of knowledge-intensive technological equipment with extended functionality. The innovative moment of this work is the development of hybrid metalworking equipment with numerical control and writing a unique postprocessor to it, which allows to realize all functional possibilities of this machine system and the technology of combined processing as a whole. Special tooling and tools providing all the necessary requirements for the process of surface hardening of HEH HFC were designed and manufactured. The conducted complex of works and approbation of the technology of integrated processing in real conditions in comparison with traditional methods of construction of technological process of parts manufacturing allowed to obtain the following results: increase in the productivity of processing by 1.9 times; exclusion of possibility of scrap occurrence at finishing grinding; reduction in auxiliary and preparatory-tasking time; and reduction in inter-operational parts backlogs. Full article

Indentation is a versatile method to assess the hardness of different materials along with their elastic properties. Recently, powerful approaches have been developed to determine further material properties, like yield strength, ultimate tensile strength, work-hardening rate, and even cyclic plastic properties, by a combination of indentation testing and computer simulations. The basic idea of these approaches is to simulate the indentation with known process parameters and to iteratively optimize the initially unknown material properties until just a minimum error between numerical and experimental results is achieved. In this work, we have developed a protocol for instrumented indentation tests and a procedure for the inverse analysis of the experimental data to obtain material parameters for time-dependent viscoplastic material behavior and kinematic and isotropic work-hardening. We assume the elastic material properties and the initial yield strength to be known because these values can be determined independently from indentation tests. Two optimization strategies were performed and compared for identification of the material parameters. The new inverse method for spherical indentation has been successfully applied to martensitic steel. Full article

This paper delves into the impact of the damage accumulation effect, which leads to the degradation of material strength and stiffness, on the seismic resistance of transmission towers. Building upon the elastic–plastic finite element theory, a mixed hardening constitutive model is derived for circular steel tubes, standard elements in transmission towers, incorporating the damage accumulation effect. A user material subroutine, UMAT, is created within the LS–DYNA framework. The program’s validity and reliability are established through axial constant–amplitude loading tests on single steel tubes. The subroutine is employed to conduct the incremental dynamic analysis (IDA) of an individual transmission tower and to contrast it with the structure utilizing the Plastic Kinematic material model, assessing the discrepancies in tower top displacements and segment damage indices (SDIs) at both macroscopic and microscopic scales. The results shows that the Plastic Kinematic model inflates the seismic performance of the transmission tower. When considering the damage accumulation effect in structural failure, the damage index of the members increases, leading to a reduction in both the structural strength and stiffness. The dynamic response in the plastic phase becomes more pronounced, and the onset of structural failure is accelerated. Consequently, structural analysis under seismic conditions should account for the damage accumulation process. Through the delineation of member and segment damage, the extent of damage to transmission tower segments can be quantitatively assessed. Subsequently, the ultimate load–bearing capacity and the most vulnerable location of the transmission tower can be ascertained. Finally, this paper provides a detailed analysis of the transmission tower collapse process under seismic action and summarizes the mechanism of collapse for the structure. Full article

This paper describes an application of a machine learning approach for parameter optimization. The method is demonstrated for the elasto-viscoplastic model with both isotropic and kinematic hardening. It is shown that the proposed method based on long short-term memory networks allowed a reasonable agreement of stress–strain curves to be obtained for cyclic deformation in a low-cycle fatigue regime. The main advantage of the proposed approach over traditional optimization schemes lies in the possibility of obtaining parameters for a new material without the necessity of conducting any further optimizations. As the power and robustness of the developed method was demonstrated for very challenging problems (cyclic deformation, crystal plasticity, self-consistent model and isotropic and kinematic hardening), it is directly applicable to other experiments and models. Full article

The combination of kinematic and isotropic hardening models makes it possible to model the behaviour of cyclic elastic-plastic steel material, though the estimation of the hardening parameters and catching the influence of those parameters on the material response is a challenging task. In the current work, an approach for the numerical simulation of the low-cycle fatigue of AISI316L steel is presented using a finite element method to study the fatigue behaviour of the steel at different strain amplitudes and operating temperatures. Fully reversed uniaxial LCF tests are performed at different strain amplitudes and operating temperatures. Based on the LCF test experimental results, the non-linear isotropic and kinematic hardening parameters are estimated for numerical simulation. On comparing, the numerical simulation results were in very good agreement with those of the experimental ones. This presented method for the numerical simulation of the low-cycle fatigue on AISI316 stainless steel can be used for the approximate prediction of the fatigue life of the components under different cyclic loading amplitudes. Full article