Search Results (16)

The purpose of this study is to investigate the effective behaviour of a micro-cracked material whose matrix bulk and shear moduli are ruled by a linear viscoelastic Burgers model. The analysis includes a detailed study of randomly oriented and distributed cracks displaying an overall isotropic behaviour, as well as aligned cracks resulting in a transversely isotropic medium. Effective material properties are approximated with the assumption that the homogenized equivalent medium exhibits the characteristics of a Burgers model, leading to the identification of short-term and long-term homogenized modules in the Laplace–Carson space through simplified formulations. The crucial advantage of this analytical technique consists in avoiding calculations of the inverse Laplace–Carson transform. The micromechanical estimates are validated through comparisons with FE numerical simulations on 3D microstructures generated with zero-thickness void cracks of disc shape. Intersections between randomly oriented cracks are accounted for, thereby highlighting a potential percolation phenomenon. The effects of micro-cracks on the material’s behaviour are then studied with the aim of providing high-performance creep models for macrostructure calculations at a moderate computation cost through the application of analytical homogenization techniques. Full article

This paper presents a numerical study on the laser shock wave propagation in a 3D woven carbon-fiber-reinforced polymer (CFRP) material by means of detailed and homogenized finite element (FE) models. The aim of this study is to numerically characterize the shock wave response of the 3D woven CFRP in terms of back-face velocity profiles and the induced damage, and to investigate whether the detailed FE models could be effectively replaced by homogenized FE models. The 3D woven geometry was designed using the TexGen 3.13.1 software, while the numerical analyses were executed using the R11.0.0 LS-Dyna explicit FE software. A high-strain-rate behavior was considered for the matrix. The fiber bundles in the detailed models were modeled as a high-fiber-content unidirectional composite laminate, with its mechanical properties calculated by micromechanical equations. A progressive damage material model was applied to both the fiber bundles of the detailed model and the homogenized models. The results of the detailed model reveal a considerable effect of the material’s architecture on the shock wave propagation and sensitivity of the back-face velocity profile to the spot location. Consequently, the homogenized model is not capable of accurately simulating the shock wave response of the 3D woven composite. Moreover, the detailed model predicts matrix cracking in the resin-rich areas and in the bundles with high accuracy, as well as fiber failure. On the contrary, the homogenized model predicts matrix cracking in the same areas and no fiber failure. Full article

In an electromagnetic launch system, the surface of the aluminum alloy armature is subjected to high-temperature ablation, leading to the generation of significant metal vapor and the initiation of high-energy arcs. This damages the armature structure and can result in a launch failure. Enhancing the ablation resistance of the armature surface is crucial for improving launch efficiency. In this study, a model for the surface modification of an aluminum alloy armature was constructed. The impact of the CoCrNiFeAl_x surface-modified material on the resistance to ablation and structural changes of the armature during arc ablation was elucidated through molecular dynamics simulation. Results show that adding a CoCrNiFeAl_x fused cladding layer can effectively enhance the material’s high-temperature resistance. The CoCrNiFeAl_x fused cladding significantly reduces the depth of arc intrusion. The CoCrNiFeAl_x aluminum alloy model exhibits a narrower strain range on the bombarded surface and a more flattened bombardment crater shape. CoCrNiFeAl_x fused cladding helps to reduce damage from substrate bombardment. Comparing simulation results indicates that CoCrNiFeAl_0.25 performs best in high-temperature resistance and impact strength, making it the most preferred choice. This study elucidates the law of high-entropy alloy arc ablation resistance and its micromechanism in armature surface modification. It provides a theoretical basis and technical support for preparing high-entropy alloy–aluminum alloy-modified armatures with superior ablation resistance performance. Full article

Reactive Air Brazing (RAB) enables the joining of vacuum-sensitive oxide ceramics, such as Ba_0.5Sr_0.5Co_0.8Fe_0.2O_3−δ (BSCF), to metals in a one-step process. However, damage may form in ceramic or joint during RAB. In this work, experimental microstructure characterization, measurement, and prediction of local material properties using finite element analysis were combined to enlighten these damage mechanisms, which are currently not well understood. Micromechanical simulations were performed using representative volume elements. Cooling simulations indicate that small-sized CuO precipitations are most likely to cause crack initiation in BSCF during cooling. The ball-on-three-balls experiment with porous BSCF samples was analyzed numerically to determine the values of temperature-dependent BSCF fracture stresses. The inversely calibrated fracture stresses in the bulk BSCF phase are underestimated, and true values should be quite high, according to an extreme value analysis of pore diameters. Full article

Multiscale FE${}^2$ computations enable the consideration of the micro-mechanical material structure in macroscopical simulations. However, these computations are very time-consuming because of numerous evaluations of a representative volume element, which represents the microstructure. In contrast, neural networks as machine learning methods are very fast to evaluate once they are trained. Even the DNN-FE${}^2$ approach is currently a known procedure, where deep neural networks (DNNs) are applied as a surrogate model of the representative volume element. In this contribution, however, a clear description of the algorithmic FE${}^2$ structure and the particular integration of deep neural networks are explained in detail. This comprises a suitable training strategy, where particular knowledge of the material behavior is considered to reduce the required amount of training data, a study of the amount of training data required for reliable FE${}^2$ simulations with special focus on the errors compared to conventional FE${}^2$ simulations, and the implementation aspect to gain considerable speed-up. As it is known, the Sobolev training and automatic differentiation increase data efficiency, prediction accuracy and speed-up in comparison to using two different neural networks for stress and tangent matrix prediction. To gain a significant speed-up of the FE${}^2$ computations, an efficient implementation of the trained neural network in a finite element code is provided. This is achieved by drawing on state-of-the-art high-performance computing libraries and just-in-time compilation yielding a maximum speed-up of a factor of more than 5000 compared to a reference FE${}^2$ computation. Moreover, the deep neural network surrogate model is able to overcome load-step size limitations of the RVE computations in step-size controlled computations. Full article

The existing phenomenological theories of plastic forming of sheet metal lack the predictability of the influences of dislocations and precipitates on viscoplastic damage in Al-Zn-Mg alloys. This study examines the evolution of grain size that occurs when the Al-Zn-Mg alloy undergoes a hot deformation process, specifically concentrating on dynamic recrystallization (DRX). The uniaxial tensile tests are conducted at deformation temperatures ranging from 350 to 450 °C and strain rates of 0.01–1 s⁻¹. The intragranular and intergranular dislocation configurations and their interactions with dynamic precipitates are revealed by transmission electron microscopy (TEM). In addition, the MgZn₂ phase induces microvoid formation. Subsequently, an improved multiscale viscoplastic constitutive model is established that emphasizes the effect of precipitates and dislocations on the evolution of microvoid-based damage. Using a calibrated and validated micromechanical model, the simulation of hot-formed U-shaped parts is conducted through finite element (FE) analysis. During the hot U-forming process, the formation of defects is expected to have an impact on both the distribution of thickness and the level of damage. In particular, the damage accumulation rate is influenced by temperature and strain rate, and local thinning is caused by the damage evolution of U-shaped parts. Full article

A simple approach to the multiscale analysis of a plain weave reinforced composite made of basalt fabrics bonded to a high performance epoxy resin L285 Havel is presented. This requires a thorough experimental program to be performed at the level of individual constituents as well as formulation of an efficient and reliable computational scheme. The rate-dependent behavior of the polymer matrix is examined first providing sufficient data needed in the calibration step of the generalized Leonov model, which in turn is adopted in numerical simulations. Missing elastic properties of basalt fibers are derived next using nanoindentation. A series of numerical tests is carried out at the level of yarns to promote the ability of a suitably modified Mori–Tanaka micromechanical model to accurately describe the nonlinear viscoelastic response of unidirectional fibrous composites. The efficiency of the Mori–Tanaka method is then exploited in the formulation of a coupled two scale computational scheme, while at the level of textile ply the finite element computational homogenization is assumed, the two-point averaging format of the Mori–Tanaka method is applied at the level of yarn to serve as a stress updater in place of another finite element model representing the yarn microstructure as typical of FE${}^2$ based multiscale approach. Several numerical simulations are presented to support the proposed modeling methodology. Full article

The current work numerically investigates commercial polycrystalline Ag/17vol.%SnO${}_2$ composite tensile deformation behavior with available experimental data. Such composites are useful for electric contacts and have a highly textured initial material status after hot extrusion. Experimentally, the initial sharp fiber texture and the number of $\mathrm{\Sigma }$3-twins were reduced due to tensile loading. The local inhomogeneous distribution of hardness and Young’s modulus gradually decreased from nanoindentation tests, approaching global homogeneity. Many-scale simulations, including micro-macro simultaneous finite element (FE) and discrete dislocation dynamics (DDD) simulations, were performed. Deformation mechanisms on the microscale are fundamental since they link those on the macro- and nanoscale. This work emphasizes micromechanical deformation behavior. Such FE calculations applied with crystal plasticity can predict local feature evolutions in detail, such as texture, morphology, and stress flow in individual grains. To avoid the negative influence of boundary conditions (BCs) on the result accuracy, BCs are given on the macrostructure, i.e., the microstructure is free of BCs. The particular type of 3D simulation, axisymmetry, is preferred, in which a 2D real microstructural cutout with 513 Ag grains is applied. From FE results, $\mathrm{\Sigma }$3-twins strongly rotated to the loading direction (twins disappear), which, possibly, caused other grains to rotate away from the loading direction. The DDD simulation treats the dislocations as discrete lines and can predict the resolved shear stress (RSS) inside one grain with dependence on various features as dislocation density and lattice orientation. The RSS can act as the link between the FE and DDD predictions. Full article

Fatigue failure usually occurs on the subsurface in rolling bearings due to multiaxial and non-proportional fatigue loadings between rolling elements. One of the main stress components is the alternating shear stress. This paper focuses on the micromechanism of plastic accumulation and damage initiation in bearing steels under cyclic shear deformation. The distribution of subsurface shear stress in bearings was firstly investigated by finite element simulation. An atomic model containing bcc-Fe and cementite phases was built by molecular dynamics (MD). Shear stress–strain characteristics were discussed to explore the mechanical properties of the atomic model. Ten alternating shear cycles were designed to explore the mechanism of cyclic plastic accumulation and damage initiation. Shear stress responses and evolutions of dislocaitons, defect meshes and high-strain atoms were discussed. The results show that cyclic softening occurs when the model is in the plastic stage. Severe cyclic shear deformation can accelerate plastic accumulation and result in an earlier shear slip of the cementite phase than that under monotonic shear deformation, which might be the initiation of microscopic damage in bearing steels. Full article

Wood is an anisotropic material, the mechanical properties of which are strongly influenced by its microstructure. In wood, grain compression strength and modulus are the weakest perpendicular to the grain compared to other grain directions. FE (finite element) models have been developed to investigate the mechanical properties of wood under transverse compression. However, almost all existing models were deterministic. Thus, the variations of geometry of the cellular structure were not considered, and the statistical characteristic of the mechanical property was not involved. This study aimed to develop an approach to investigate the compression property of wood in a statistical sense by considering the irregular geometry of wood cells. First, the mechanical properties of wood under radial perpendicular to grain compression was experimentally investigated, then the statistical characteristic of cell geometry was extracted from test data. Finally, the mechanical property of wood was investigated using the finite element method in combination with the Monte Carlo Simulation (MCS) techniques using randomly generated FE models. By parameter sensitivity analysis, it was found that the occurrence of the yield points was caused by the bending or buckling of the earlywood axial tracheid cell wall in the tangential direction. The MCS-based stochastic FE analysis was revealed as an interesting approach for assessing the micro-mechanical performance of wood and in assisting in understanding the mechanical behavior of wood based on its hierarchical structure. Full article

A modified micromechanics failure criterion (MMF3) based multi-scale analysis strategy was proposed in this article to analyze the failure behaviors of the plain-woven fabric composites. The finite-element (FE) representative unit cell (RUC) models of different scales were first established, and the RUC based stress transformation methods were developed. The micro-scale strengths of the constituents in the unidirectional laminate were achieved based on the tested macro-scale strengths. Under the micro-scale strength invariance hypothesis, the meso-scale strengths of the fiber tows from the plain-woven fabric composites were back-calculated first and were then validated and corrected with the assistance of tested strengths of the fabric laminates. With the micro-scale RUC and the calculated meso-scale strengths of the fiber tows, the micro-scale strengths of the constituents suitable for the plain-woven fabric composites were determined. The multi-scale analysis procedure for the plain-woven fabric composites was then established in providing a more direct failure observation at the constituent level. Open-hole compression specimens were tested according to the ASTM standard D6484, and the failure of the open-hole fabric laminate was simulated with the proposed multi-scale strategy. The numerical predictions were in good agreement with the experimental results, and the feasibility of the multi-scale strategy was validated. Full article

This paper aims to (1) study ductile fracture behavior, and (2) provide a computational tool for predicting fracture initiation in ASTM A572 Gr. 50 structural steels under axisymmetric tension loading are heated to elevated temperatures and cooled down in air and in water. Employing the post-fire test results reported in the literature for A572 Gr. 50 steels, this paper carries out coupon-level finite element (FE) simulations to capture the stress and strain fields and explore the micro-mechanism of post-fire fracture in ASTM A572 Gr. 50 steels, respectively. Numerical results show that the effects of the experienced temperature and cooling method on fracture parameters are more significant for the steels cooled after being heated to temperatures from 800 °C to 1000 °C than those from 500 °C to 700 °C, due to microstructural changes during the cooling process. Air-cooled and water-cooled specimens show an improvement and a significant reduction in ductility, respectively. A modified void growth model (VGM) is proposed by introducing two additional temperature-dependent functions, through which the effects of elevated temperature and cooling method on fracture behavior are quantitatively analyzed. Limitations of this study are also discussed. Full article

To improve the representativeness of a real microstructural cut-out for modeling purposes, a numerical method named as “boundary pixel color alteration (BPCA)” is presented to modify measured 2D microstructure cut-outs. Its physical background is related to the phase growth. For the application, the precondition is that the representativeness of the microstructure is already satisfied to a certain extent. This method resolves the problem that the phase composition of a small cut-out can have a large discrepancy to the real one. The main idea is to change the pixel color among neighboring pixels belonging to different phases. Our process simultaneously maintains most of the characteristics of the original morphology and is applicable for nearly all kinds of multi-phase or polycrystalline metallic alloys, as well. From our axisymmetric finite element (FE) simulations (ABAQUS ) applied with 2D real microstructures, it shows that the volume ratios of microstructural phases, as a function of the structure position to the symmetric axis, converge to phase area ratios in the 2D cut-out, even though the axisymmetric element volume is position dependent. A mathematical proof provides the reason for the aforementioned convergence. As examples to achieve real compositions and to numerically prove the aforementioned convergence, four different materials including multiphase polycrystals are implemented. An improvement of the predicted FE result is presented for the application of a modified microstructure (with a higher representativeness) compared to the original one. Full article

In this contribution, the ratcheting behavior and local field distribution of unidirectional metal matrix composites are investigated under cyclic loading. To that end, we extended the finite-volume direct averaging micromechanics (FVDAM) theory by incorporating the rule of nonlinear kinematic hardening. The proposed method enables efficient and accurate simulation of the ratcheting behavior of unidirectional composites. The local satisfaction of equilibrium equations of the FVDAM theory facilitates quick and rapid convergence during the plastic iterations. To verify the proposed theory, a finite-element (FE) based unit cell model is constructed with the same mesh discretization. The remarkable correlation of the transverse response and local field distribution generated by the FVDAM and FE techniques demonstrates the effectiveness and accuracy of the proposed models. The stress discontinuities along the fiber/matrix interface that are generic to the finite-element theory are absent in the FVDAM prediction. The effects of thermal residual stresses induced during the consolidation process, as well as fiber orientations, are revealed. The generated results indicate that the FVDAM is well suited for simulating the elastic-plastic ratcheting behavior of metal matrix composites, which will provide the conventional finite-element based technique with an attractive alternative. Full article

In this paper, an image-based micromechanical model for an asphalt mixture’s rheological mechanical response is introduced. Detailed information on finite element (FE) modeling based on X-ray computed tomography (X-ray CT) is presented. An improved morphological multiscale algorithm was developed to segment the adhesive coarse aggregate images. A classification method to recognize the different classifications of the elemental area for a confining pressure purpose is proposed in this study. Then, the numerical viscoelastic constitutive formulation of asphalt mortar in an FE code was implemented using the simulation software ABAQUS user material subroutine (UMAT). To avoid complex experiments in determining the time-dependent Poisson’s ratio directly, numerous attempts were made to indirectly obtain all material properties in the viscoelastic constitutive model. Finally, the image-based FE model incorporated with the viscoelastic asphalt mortar phase and elastic aggregates was used for triaxial compressive test simulations, and a triaxial creep experiment under different working conditions was conducted to identify and validate the proposed finite element approach. The numerical simulation and experimental results indicate that the three-dimensional microstructural numerical model established can effectively analyze the material’s rheological mechanical response under the effect of triaxial load within the linear viscoelastic range. Full article