Search Results (82)

This study analyzed the dynamic behavior of EN C45 structural steel under impulse loading generated by a pressure wave. The experiments were conducted on a special test rig using two load configurations: (I) direct contact of the load with the sample surface and (II) detonation at a distance of 30 mm. Depending on the loading conditions, the specimens were fragmented or developed extensive internal cracks and plastic deformations. To complement the experimental program, hybrid numerical simulations were performed using the finite element method (FEM), smoothed particles hydrodynamics (SPH), and coupled Euler–Lagrange (CEL) approach. A modified Johnson–Cook (JC) model was used to account for dynamic damage and cracks. Computed tomography (CT) and metallographic analyses provided detailed information on the formation of cracks in MnS inclusions, brittle cracks near the sample axis, and shear deformation zones away from the axis. These observations allowed direct correlation with the predicted numerical deformation and damage fields. The innovative nature of this work lies in the combination of three complementary computational techniques with computed tomography analysis and microstructure analysis, providing a comprehensive framework for describing and confirming the mechanisms of damage and fragmentation of structural steels under explosive loading. Full article

To improve the ballistic resistance of hydrogen storage tank-grade 316L austenitic stainless steel (ASS) plates that are prone to shear plugging failure under blunt projectile impact, this study proposes a non-bonded bilayer protective configuration: covering the 316L ASS substrate with a thin front layer of 2024-T351 aluminum alloy (AA) plate. Ballistic impact tests were performed on monolithic 5 mm thick 316L ASS plates and bilayer targets composed of a 2.05 mm thick 2024-T351 AA plate and a 5 mm thick 316L ASS substrate (total thickness: 7.05 mm), using a single-stage light gas gun combined with high-speed photography. Parallel explicit dynamics models were established using ABAQUS/Explicit, incorporating a modified Johnson–Cook constitutive model and a Lode-dependent Modified Mohr–Coulomb (MMC) fracture criterion, thereby enabling rigorous mutual validation between experimental results and numerical simulations. Results demonstrate that the addition of a mere 2.05 mm thick aluminum alloy front layer significantly enhances the ballistic limit velocity (BLV) of the 5 mm thick 316L stainless steel target plate, increasing it from 167.5 m/s to 250.7 m/s. The enhancement mechanism is closely related to the transition in the failure mode from localized shear plugging to a combination of bulging, dishing, and plugging. This shift substantially improves the structure’s overall plastic deformation capacity and energy dissipation efficiency. This research provides an effective solution and establishes a reliable experimental–numerical benchmark for the lightweight, impact-resistant design of hydrogen storage tanks. Full article

This study investigates the mechanical response characteristics and damage evolution behavior of TC4 alloy through quasi-static/dynamic coupled experimental methods. Quasi-static tensile tests at varying temperatures (293 K, 423 K, and 623 K) were conducted using a universal testing machine, while room-temperature dynamic tensile tests (strain rate 1000–3000 s⁻¹) were performed with a Split Hopkinson Tensile Bar (SHTB). Key findings include the following: (1) Significant temperature-softening effect was observed, with flow stress decreasing markedly as temperature increased; (2) Notch size effect influenced mechanical properties, showing 50% enhancement in post-fracture elongation when notch radius increased from 3 mm to 6 mm; and (3) Strain-hardening effect exhibited rate dependence under dynamic loading, with reduced hardening index within the tested strain rate range. The Johnson–Cook constitutive model and failure criterion were modified and parameterized based on experimental data. A 3D tensile simulation model developed in ABAQUS demonstrated strong agreement with experimental results, achieving a 0.97 correlation coefficient for load–displacement curves, thereby validating the modified models. Scanning electron microscopy (SEM) analysis of fracture surfaces revealed temperature- and strain rate-dependent microstructural characteristics, dominated by ductile fracture mechanisms involving microvoid nucleation, growth, and coalescence. This research provides theoretical foundations for analyzing Ti alloy structures under impact loading through established temperature–rate-coupled constitutive models. Full article

To accurately assess the effect of different plate thicknesses on the residual stress field of laser shock peened GH3039 superalloy, residual stress measurements were performed on GH3039 alloy plates with thicknesses of 2 mm and 5 mm after laser shock peening (LSP) treatment. Both quasi-static and high strain rate mechanical tests of GH3039 were conducted, and the Johnson-Cook (J-C) constitutive equation for GH3039 alloy at specific strain rates was fitted based on the experimental results. To obtain the parameter C in the J-C constitutive equation of GH3039 alloy under ultra-high strain rates, a modified method was proposed based on LSP experiment and finite element simulation results. Using the modified GH3039 alloy J-C constitutive equation, numerical simulations and comparative analyses of the residual stress field of GH3039 alloy plates of different thicknesses under LSP were carried out using ABAQUS software. The simulated residual stress fields of laser-shocked GH3039 alloy plates of different thicknesses were in good agreement with the experimental measurements, indicating that the modified GH3039 alloy J-C constitutive equation can accurately predict the mechanical behavior of GH3039 alloy under ultra-high strain rates. Based on the modified GH3039 alloy J-C constitutive equation, the effect of different plate thicknesses on the residual stress distribution of laser-shocked GH3039 alloy was studied, along with the underlying mechanisms. The unique distribution characteristics of residual stresses in laser-shocked GH3039 plates with varying thicknesses are primarily attributed to differences in plate bending stiffness and the detrimental coupling effects of reflected tensile waves. Full article

This study investigates the long-term performance of flexible anti-collision rings after 12 years of service on the Xiangshan Port Highway Bridge. Stepwise loading–unloading tests at multiple loading rates (0.8–80 mm/s) were performed on the anti-collision rings, with full-field strain measurement via digital image correlation (DIC) technology. The results show that: The mechanical response of the anti-collision ring shows significant asymmetric tension–compression, with the tensile peak force being 6.8 times that of compression. A modified Johnson–Cook model was developed to accurately characterize the tension–compression force–displacement behavior across varying strain rates (0.001–0.1 s⁻¹). The DIC full-field strain analysis reveals that the clamping fixture significantly influences the tensile deformation mode of the anti-collision ring by constraining its inner wall movement, thereby altering strain distribution patterns. Despite exhibiting a corrosion gradient from severe underwater degradation to minimal surface weathering, all tested rings demonstrated consistent mechanical performance, verifying the robust protective capability of the rubber coating in marine service conditions. Full article

In the industrial practice of metal forming, the consistent and reasonable characterization of the material behavior under the coupling effect of strain, strain rate, and temperature on the material flow stress is very important for the design and optimization of process parameters. The purpose of this work was to establish an appropriate constitutive model to characterize the rheological behavior of a hot-formed steel plate (22MnB5 steel) produced through the TSCR (Thin Slab Casting and Rolling) process under practical deformation temperatures (150–250 °C) and strain rates (0.001–3000 s⁻¹). Subsequently, the material flow behavior was modeled and predicted using the Johnson–Cook flow stress constitutive model. In this study, uniaxial tensile tests were conducted on 22MnB5 steel at room temperature under varying strain rates, along with elevated-temperature tensile tests at different strain rates, to obtain the engineering stress–strain curves and analyze the mechanical properties under various conditions. The results show that during room-temperature tensile testing within the strain rate range of 10⁻³ to 300 s⁻¹, the 22MnB5 steel exhibited overall yield strength and tensile strength of approximately 1500 MPa, and uniform elongation and fracture elongation of about 7% and 12%, respectively. When the strain rate reached 1000–3000 s⁻¹, the yield strength and tensile strength were approximately 2000 MPa, while the uniform elongation and fracture elongation were about 6% and 10%, respectively. Based on the experimental results, a modified Johnson–Cook constitutive model was developed and calibrated. Compared with the original model, the modified Johnson–Cook model exhibited a higher coefficient of determination (R²), indicating improved fitting accuracy. In addition, to predict the material’s damage behavior, three distinct specimen geometries were designed for quasi-static strain rate uniaxial tensile testing at ambient temperature. The Johnson–Cook failure criterion was implemented, with its constitutive parameters calibrated through integrated finite element analysis to establish the damage model. The determined damage parameters from this investigation can be effectively implemented in metal forming simulations, providing valuable predictive capabilities regarding workpiece material performance. Full article

The aim of this study was to analyse in detail the effect of varying the parameters of the Johnson–Cook (JC) material model on the results of a numerical simulation of the orthogonal turning process of the Ti6Al4V titanium alloy. The first step involved an experimental study, including the recording of cutting force components and temperature, as well as the measurement of chip geometry, which was used to validate the FEM simulation. This was followed by a sensitivity analysis of the JC model with respect to five parameters, namely A, B, C, m, and n, each modified independently by ±20%. The effects of these changes on cutting forces, cutting zone temperature, stresses, and chip geometry were evaluated. The results showed that parameters A, B, and m had the greatest influence on the physical quantities analysed, while C and n are of secondary importance. The analysis highlighted the need for precise calibration of the JC model parameters, especially when modelling machining processes involving difficult-to-machine materials. The results provided practical guidance for optimising the selection of constitutive parameters in machining simulations. Full article

Boron steel welded tubes show strong potential as blanks in the integrated hot gas forming–quenching process for fabricating complex thin-walled automotive parts. Nonetheless, the non-uniform characteristics of the base metal and the weld in the high-heat welded tube can result in uneven deformation during the bulging process. This inconsistency hampers precise predictions of the deformation behavior of the welded tubes at high temperatures. Accordingly, this research explored the flow characteristics and mechanical properties of PHS1500 boron steel welded tubes. This research was conducted at 850 °C and 900 °C, with strain rates of 0.01 s⁻¹–1 s⁻¹. The Johnson–Cook model was modified for both the base metal and the weld using experimental stress–strain data. Meanwhile, to assess the model precisions, the correlation coefficient r and the average absolute relative error (AARE) were employed. Finally, hot gas forming of PHS1500 boron steel welded tubular parts with complex shapes was predicted through a finite element analysis. This research showed a positive correlation of the strain rate with both the yield and tensile strengths in the base metal and the weld. The average yield strength and tensile strength of the weld were 12.8% and 3.9% higher than those of the base metal, respectively. The r and AARE of the modified Johnson–Cook constitutive model for the base metal’s and the weld’s flow stress were 0.99 and 2.23% and 0.982 and 5.31%, respectively. The maximum deviation in the predictions of the distribution of the wall thickness of a typical cross-section of the formed complex-shaped tubular parts was less than 8%. Full article

An absolutely conflicting value for the incorporation of the Lode parameter into a fracture criterion was reported in the literature when predicting the ballistic resistance of metallic plates failing through shear plugging. In this study, a combined experimental–numerical investigation was conducted to understand the dynamic shear fracture behavior under compression–shear stress states. Flat-hat-shaped specimens of 30CrMnSiNi2A high-strength steel were loaded using a Split Hopkinson Pressure Bar apparatus, combining the ultra-high-speed photography technique, digital image correlation method, and microstructure observation. Parallel finite element simulations were performed using both a modified Johnson–Cook (MJC) fracture criterion or an extended Xue–Wierzbicki (EXW) fracture criterion with Lode dependence to reveal the value of the Lode parameter incorporation. It was found that deformed shear bands with a width of approximately 0.14 mm form at a critical impact velocity. The EXW criterion correctly predicts the critical fracture velocity and estimates the fracture initiation instants within an error of 5.3%, whereas the MJC fracture criterion overestimates the velocity by 14.3%. Detailed analysis shows that the EXW criterion predicts a combined failure mechanism involving ductile fracture and material instability, while the MJC fracture criterion attributes the failure exclusively to material instability. The improved accuracy achieved by employing the Lode-dependent EXW fracture criterion may be attributed to the compression–shear stress state and the accurate prediction of the failure mechanism of the dynamic shear fracture. Full article

In the context of Al-Kharj city, which is steadily advancing as an industrial and manufacturing hub within Saudi Arabia, this study has significant relevance. The city’s focus on metal forming, fabrication, and materials engineering makes it crucial to optimize processes such as hot deformation of metallic alloys for various sectors, including aerospace, automotive, oil and gas, and structural applications. By assessing and comparing phenomenological and physical material models for nickel, aluminum, titanium, and iron-based alloys, this study aids Al-Kharj industries in advancing their process simulation and predictive performance. Thus, this study aims to evaluate the proposed phenomenological and physically based constitutive models for Ni-, Al-, Ti-, and Fe-based alloys to enhance the accuracy of high-temperature deformation simulations. Phenomenological models investigated include the Johnson–Cook (JC), Fields and Backofen (FB), and Khan–Huang–Liang (KHL) formulations, while the Zerilli–Armstrong (ZA) model represents the physical category. Additionally, various modifications to these models are explored. Model parameters are calibrated using the Levenberg–Marquardt algorithm to minimize mean square error. Performance is assessed through key statistical metrics, including the correlation coefficient (R), average absolute relative error (AARE), and root mean square error (RMSE). Of the 32 models analyzed, a modified version of the JC model delivers the highest accuracy across all alloys. Furthermore, four other modifications, one each for the JC and ZA models and two for the FB model, exhibit superior predictive capability for specific alloys. This makes this study valuable not just academically, but also as a practical resource to boost Al-Kharj’s industrial competitiveness and innovation capacity. Full article

The cold spray (CS) process has gained momentum as an additive manufacturing technology, due to its low processing temperatures. Computational modelling can accompany CS experiments to optimise deposition parameters, as well as predict coating properties and their final performance. A commonly used plasticity model is the Johnson–Cook (JC) model; however, its accuracy is limited at the high strain rates typical of cold spray. This study aims to assess the robustness of predictions using a modified JC model, particularly for two material systems of commercially pure titanium (CP-Ti) and Al6061-T6, and feedstock powders of two sizes and three morphologies. CP-Ti powders of spherical and irregular morphologies were sprayed onto CP-Ti substrates using a Titomic TKF1000 cold spray system. The cross-sectional splat profiles and flattening ratios were compared against smoothed particle hydrodynamics (SPH) simulations. The deposition process of particles was simulated using a modified JC model, implemented as an ABAQUS (2020) VUHARD user subroutine programme. The results showed that SPH simulations predicted the depth of impact, the splat profiles and the flattening ratios. Additionally, the simulations indicated that the impacting particle temperature remained below the melting point of CP-Ti throughout the process. Lastly, it was demonstrated that the irregular CP-Ti feedstock showed greater tendency of restitution than spherical feedstock. Full article

Lüders plateau, a frequently observed phenomenon in uniaxial tensile tests of 40CrNiMoA high-strength steel, significantly influences material fracture behavior but is often neglected in characterizing metal plasticity and fracture properties. This study aims to develop a modified Johnson–Cook-2 (MJC-2) plasticity model incorporating Lüders plateau effects and evaluate its predictive capability for impact response. A series of mechanical tests were conducted and the plasticity model was calibrated through an experimental–numerical approach. Taylor impact and ballistic impact tests were conducted using a single-stage gas gun, with corresponding numerical simulations performed in finite element (FE) software. The results demonstrate that the MJC-2 model provides superior accuracy in predicting the fracture behavior of both targets and Taylor rods, as well as ballistic limit velocities (BLVs). Compared to models neglecting Lüders plateau, MJC-2 significantly enhances prediction precision. Full article

Friction has a significant impact on chip formation, so modeling it accurately is crucial in numerical cutting simulations. However, there is still controversy regarding the application scope and effectiveness of various friction models. A two-dimensional orthogonal cutting thermomechanical coupled finite element model is established. Critical strain values, recrystallization temperature, and recrystallization flow stress are introduced, and a power-law-modified softening coefficient is used to modify the standard Johnson–Cook constitutive model to simulate material mechanical properties. Zorev’s friction model, velocity-dependent friction model, and temperature-dependent friction model are separately employed to describe the friction behavior between the tool and workpiece. The contact and friction characteristics between the workpiece and tool, material damage, and temperature field are evaluated. Predicted cutting forces are compared and analyzed with experimental values. The friction coefficient can adjust the contact length between the tool and chip, the high-temperature range on the tool surface, and the fluctuation of temperature throughout the entire cutting process. The friction coefficient is more sensitive to sliding velocity, and the temperature distribution is more sensitive to the friction model than to different working conditions. Whether by modifying the friction coefficient or maximum friction shear stress, and regardless of whether adding parameters affected by velocity or temperature changes the fluctuation range, period, and local peaks of the cutting force prediction curve, improving the accuracy of predictions within certain working condition ranges to some extent. However, the overall trend of error fluctuations obtained from these friction models is similar, and the accuracy of predictions from these friction models tends to become more inaccurate with increasing cutting thickness. Full article

This study investigated the compressive behavior of 30 vol.% boron carbide (B₄C)/2024 aluminum (Al) composites under quasi-static and dynamic loading at different temperatures. Building on the experimental findings, the Johnson–Cook (JC) model was modified, and a complete failure criterion was proposed. These were validated in Abaqus employing the user subroutine for hardening (VUHARD), which incorporated both the modified JC (MJC) model and the complete failure criterion. Experimental results revealed that strain softening was an important feature of the stress–strain curve. The analysis of mechanisms contributing to yield strength revealed that Taylor and load transfer mechanisms dominated, accounting for 89.6% of the total enhancement. Microstructural analysis identified particle fracture and matrix damage were the primary mechanisms driving material failure. Microcracks mainly propagated through the matrix and interface or directly through the ceramic particles and the matrix. The MJC model demonstrated high accuracy in describing the plastic deformation behavior of the composite, with a mean absolute error (MAE) below 15% under dynamic loading. Further simulation confirmed that finite element analyses using the VUHARD subroutine accurately captured the plastic deformation and crack propagation behaviors of the composite under dynamic loading. This study offers a novel approach to describe the plastic deformation and failure behaviors of ceramic-reinforced aluminum matrix composites under dynamic loading conditions. Full article

The coupling effects of electrical pulse, temperature, strain rate, and strain on the flow behavior and plasticity of 7075-T6 aluminum alloy were investigated and characterized. The isothermal tensile test and electrically assisted isothermal tensile test were performed at the same temperature, and the typical models were further embedded in ABAQUS for numerical simulation to illustrate the electroplastic effect. The results showed that electrical pulses reduced deformation resistance but greatly increased elongation. Compared with the traditional Johnson–Cook model, the proposed modified electroplasticity constitutive equations have a certain improvement in calibration accuracy for a highly nonlinear and thermoelectric coupling dynamic behavior. Moreover, combined with the electrically assisted three-point bending experiment, it was found that the springback angle decreases with the increase in current density. This is very close to the experimental result, further verifying the effectiveness of the thermoelectric coupling constitutive equation. Full article