Search Results (80)

Two-dimensional viscoplastic nonlinear analyses of the 2019 Feijão Dam 1 failure are performed using the finite difference program FLAC 8.1 with the user-defined constitutive models PM4SiltR and PM4Sand to assess how a series of commonly used engineering approaches can approximate the observed failure. A brief history of Feijão Dam 1, its failure, and the findings from two previous independent failure investigations are summarized. The present study uses the site characterization from those prior studies to develop the dam cross section, obtain material index properties, and establish groundwater conditions but uses alternative techniques for characterizing undrained shear strengths. The simulations show that the dam was marginally stable against long-term consolidated, undrained conditions and that modest loading changes were sufficient to trigger failure with deformation patterns consistent with the observed failure. The simulations further show that the collapse could have been triggered by a modest wetting event, ongoing drilling activities, or a combination of both mechanisms. Result sensitivity to choices in the calibration process and the numerical solution scheme are evaluated. The implications of these results on the use of commonly used engineering approaches for system-level time-dependent analyses and on long-term slope stability assessment procedures in practice are discussed. The results of this study provide support for the use of these analysis methods and engineering procedures in practice despite their simplifications and associated limitations. Full article

As a critical factor for the magnetic properties of grain-oriented silicon steel, the orientation accuracy of shear bands is closely related to the matrix orientation deviation from {111}<112>. This work investigates the orientation rotation of shear bands in {111}<112> matrices with various types of deviation during cold rolling, using a visco-plastic self-consistent model that incorporates a two-dimensional inclined angle of the shear band dependent on matrix orientation. When the matrix orientation deviates from {111}<112> along φ₁, φ₂, or both axes, the φ₁ deviation of the shear band decreases, and the φ₂ deviation is larger than φ₁. Compared with a uniaxially deviated {111}<112> matrix, a biaxially deviated matrix along φ₁ and φ₂ axes produces a higher shear band deviation from Goss due to the increased φ₂ deviation. This suggests that improving the orientation accuracy of the shear band is necessary to decrease the matrix deviation from {111}<112> in the φ₁ and especially φ₂ axes. Full article

Modeling of friction stir welding (FSW) is challenging, as there are large gradients in both strain rate and temperature (typically between 450 and 500 °C in aluminum alloys) that must be accounted for in the constitutive law of the material being joined. Constitutive laws are most often calibrated using flow stresses from hot compression or hot torsion testing, where strain rates are much lower than those seen in the stir zone of the FSW process. As such, the current work employed a recently developed method to measure flow stresses at high strain rates and temperatures in AA 2219-T67, and these data were used in the development of a finite element (FE) simulation of FSW. Because heat generation during FSW is primarily a function of friction between the rapidly spinning tool and the plate, the choice of friction law and associated parameters were also studied with respect to FE model predictions. It was found that the Norton viscoplastic friction law provided the most accurate modeling results, for both the transient and steady-state phases of an FSW plunge experiment. It is likely that the superior performance of the Norton law was its ability to account for temperature and rate sensitivity of the plate material sheared by the tool, while the Tresca-limited Coulomb law favored contact pressure, with essentially no temperature or rate dependence of the local material properties. With optimized friction parameters and more accurate flow stresses for the weld zone, as measured by a high-pressure shear test, a 65% overall reduction in model error was achieved, compared to a model that employed a material law calibrated with hot compression or hot torsion test results. Model error was calculated as an equally weighted comparison of temperatures, torques, and forces with experimentally measured values. Full article

Epoxy resins are extensively employed as adhesives and matrices in fibre-reinforced composites. As polymers, they possess a viscoelastic nature and are prone to creep and stress relaxation even at room temperature. This phenomenon is also responsible for time-dependent failure or creep fracture due to cumulative strain. Several constitutive equations have been used to describe the mechanical time-dependent response of polymers. These models have been proposed over the past six decades, with minimal direct and practical confrontation. Each model is associated with a specific application or research group. This work assesses the predictive performance of four distinct time-dependent constitutive models based on experimental data. The models were deemed sufficiently straightforward to be readily integrated into practical engineering analyses. A range of loading cases, encompassing constant strain rate, creep, and relaxation tests, were conducted on a commercial epoxy resin. Model parameter calibration was conducted with a minimum data set. The extrapolative predictive capacity of the models was evaluated for creep loading by extending the tests to five decades. The selected rheological models comprise two viscoelastic models based on Volterra-type integrals, as originally proposed by Schapery and Rabotnov; one viscoplastic model, as originally proposed by Norton and Bailey; and the Burger model, in which two springs and two dashpots are combined in a serial and parallel configuration. The number of model parameters does not correlate positively to superior performance, even if it is high. Overall, the models exhibited satisfactory predictive performance, displaying similar outcomes with some relevant differences during the unloading phases. Full article

The evolution of the crystallographic texture after severe plastic deformation (SPD) of the aluminum alloy AA7075, commonly used in the aeronautical and automotive industries, depends on the parameters of the applied deformation process. In this paper, a combination between experimental ECAP processing and numerical simulation using the visco-plastic self-consistent methodology (VPSC) was carried out. The limitations in the homogeneity of the mechanical properties and texture of the parts processed via ECAP can be improved by an adequate choice of the processing route. According to the literature, the most effective route to increase the properties of this material is the Bc route. However, due to the two-fold symmetry along the extrusion axis, the Bc route cannot be used in the components under study. Because of this, it was decided to study C and modified C routes. The simulation results showed the characteristic fibers of the ECAP process measured through X-ray diffraction. The texture analysis shows that the most effective route to obtain a more homogenous shear deformation and therefore reduce the grain size is the Bc route, followed by the modified C route and finally the C route. Full article

Two rheological Burgers–Faraday models and rheological dynamical systems were created by using two new rheological models: Kelvin–Voigt–Faraday fractional-type model and Maxwell–Faraday fractional-type model. The Burgers–Faraday models described in the paper are new models that examine the dynamical behavior of materials with coupled fields: mechanical stress and strain and the electric field of polarization through the Faraday element. The analysis of the constitutive relation of the fractional order for Burgers–Faraday models is given. Two Burgers–Faraday fractional-type dynamical systems were created under certain approximations. Both rheological Burgers-Faraday dynamic systems have two internal degrees of freedom, which are introduced into the system by each standard light Burgers-Faraday bonding element. It is shown that the sequence of bonding elements in the structure of the standard light Burgers-Faraday bonding element changes the dynamic properties of the rheological dynamic system, so that in one case the system behaves as a fractional-type oscillator, while in the other case, it exhibits a creeping or pulsating behavior under the influence of an external periodic force. These models of rheological dynamic systems can be used to model new natural and synthetic biomaterials that possess both viscoelastic/viscoplastic and piezoelectric properties and have dynamical properties of stress relaxation. Full article

In the longstanding development of hydrate-bearing sediment (HBS) reservoirs, slow and permanent deformation of the formation will occur under the influence of stress, which endangers the safety of hydrate development projects. This paper takes hydrate-bearing sandy sediment (HBSS) as the research object and conducts triaxial compression creep tests at different saturation degrees (20%, 30%, and 40%). The results show that the hydrate-containing sandy sediments have strong creep characteristics, and accelerated creep phenomenon will occur under the long-term action of high stress. The longstanding destructive power of the specimen progressively raises with the increase in hydrate saturation, but the difference in the triaxial strength of the specimen progressively increases. This indicates that the damage to the hydrate structure during long-term loading is the main factor causing the strength decrease. Further, a new nonlinear creep constitutive model was developed by using the nonlinear Burgers model in series with the fractional-order viscoplastic body model, which can well describe the creep properties of HBSS at different saturation levels. Full article

Rutting is a significant form of pavement distress that arises from irreversible strains accumulating along wheel paths, directly impacting pavement safety. This research investigates the effectiveness of nanocarbon-coated micronized calcium carbonate powder as a modified filler to mitigate rutting, utilizing numerical methods via finite element software. The study specifically examines the addition of 5% by weight of this modified filler to the asphalt mix. To validate the numerical results, laboratory wheel-tracking tests were conducted on samples incorporating both conventional and modified fillers. The findings reveal that the modified calcium carbonate filler enhances the asphalt’s resistance to rutting, with the 5% inclusion demonstrating a marked improvement in durability and performance. The study also underscores the necessity of characterizing the elastic and visco-plastic properties of materials through rigorous testing methods, such as elastic modulus and dynamic creep tests, to better understand their behavior under load. Numerical analysis based on linear elastic conditions was prioritized over viscous conditions to effectively compare the results of these specialized materials. The strong correlation between the numerical simulations and laboratory results reinforces the effectiveness of finite element methods in predicting pavement behavior and optimizing asphalt mixtures. Full article

In this paper, the influence mechanism of ultrasound on plastic flow and microstructure features of the aluminum–copper friction stir lap welding (Al/Cu-FSLW) process is systematically investigated by adjusting the welding speed and improving the shear rheology in the plastic stirring zone. Through adjusting the ultrasonic vibration and welding speed, the directional control of mechanical properties is realized. It is found that increasing the welding speed properly is beneficial to enhance the mechanical shear between the tool and the workpiece, thus forming more staggered layered structures at the copper side and improving the tensile strength of the weld. The acoustic softening enhances the viscoplastic fluid mixing and strengthens the mechanical interlock of the Al/Cu lap interface. As the welding speeds increase or ultrasonic vibration is applied, the thickness of Al/Cu intermetallic compound (IMC) decreases, and the tensile strength and elongation of the Al/Cu joints are enhanced. Compared with adjusting the welding speed, the ultrasonic vibration can further refine the copper particles which are stirred into the plastic zone, and the thinning effect of ultrasound on IMC layers is better than that of increasing welding speed. At the welding speed of 60 mm/min, the IMC layer thickness is reduced by 42% under ultrasonic effect. In three welding speed conditions, the UV reduced the absolute value of the effective heat of formation (EHF) for Al₂Cu and Al₄Cu₉ and suppressed the formation of AlCu phase. Meanwhile, only when the welding speed is increased from 60 mm/min to 100 mm/min can the formation of AlCu be suppressed. Under the ultrasonic optimization, the stable improvement of welding efficiency is ensured. Full article

While zinc die-casting alloy Zamak is widely used in vehicles and machines, its solidified state has yet to be thoroughly investigated experimentally or mathematically modeled. The material behavior is characterized by temperature and rate sensitivity, aging, and long-term influences under external loads. Thus, we model the thermo-mechanical behavior of Zamak in the solid state for a temperature range from −40 °C to 85 °C, and the aging state up to one year. The finite strain thermo-viscoplasticity model is derived from an extensive experimental campaign. This campaign involved tension, compression, and torsion tests at various temperatures and aging states. Furthermore, the thermo-physical properties of temperature- and aging-dependent heat capacity and heat conductivity are considered. One significant challenge is related to the multiplicative decompositions of the deformation gradient, which affects strain and stress measures relative to different intermediate configurations. The entire model is implemented into an implicit finite element program and validation examples at more complex parts are provided so that the predicability for complex parts is available, which has not been possible so far. Validation experiments using digital image correlation confirm the accuracy of the thermo-mechanically consistent constitutive equations for complex geometrical shapes. Moroever, validation measures are introduced and applied for a complex geometrical shape of a zinc die casting specimen. This provides a measure of the deformation state for complex components under real operating conditions. Full article

This article is devoted to the study of heat exchange of a heated flow of waxy oil in a pipe. Heat exchange between the waxy oil flow and the surrounding environment decreases the oil temperature and sharply increases the rheological properties. The appearance of a solid-like region within the yield-stress fluid flow is a non-trivial problem. This flow property greatly complicates the numerical solution of the system of equations governing the flow and heat transfer of viscoplastic fluids. The Bingham–Papanastasiou model allows one to solve the problem by regularizing the formula for effective molecular viscosity. The novelty of this work lies in establishing the dependence of the Nusselt number on the Reynolds and Bingham numbers for the flow of viscoplastic fluid in a pipe. Via calculations, velocity, temperature, and pressure distributions in the flow were obtained for Bingham numbers ranging from 1.7 to 118.29 and Reynolds numbers ranging from 104 to 2615. The Nusselt number dependence increases with the increase in the Reynolds number and decreases with the decrease in the Bingham number along the pipe length. Full article

In designing accurate constitutive models, it is important to investigate the stability of the response obtained by means of these models to perturbations in operator and input data because the properties of materials at different structural-scale levels and thermomechanical influences are stochastic in nature. In this paper, we present the results of an application of the method developed by the authors to a numerical study of the stability of multilevel models to different perturbations: perturbations of the history of influences, initial condition perturbations, and parametric operator perturbations. We analyze a two-level constitutive model of the alpha-titanium polycrystal with a hexagonal closed packed lattice under different loading modes. The numerical results obtained here indicate that the model is stable to perturbations of any type. For the first time, an analytical justification of the stability of the considered constitutive model by means of the first Lyapunov method is proposed, and thus the impossibility of instability in models with modified viscoplastic Hutchinson relations is proved. 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

Sn-Ag-Cu-Bi (SAC-Bi) alloys are gaining popularity as a potential replacement for current lead-free solder alloys in microelectronic packages. In this study, the tensile and viscoplastic behaviors of eight SAC-Bi alloys with 0, 1 wt.%, 2 wt.%, and 3 wt.% Bi content were investigated. The samples of these eight alloys were cast, aged at room temperature, 75 °C and 125 °C, and tensile-tested at rates of 0.1/s, 0.01/s, and 0.001/s in ambient and elevated temperature environments to facilitate the quantification of viscoplasticity using the Anand viscoplastic model. The Anand parameters of all eight alloys in the as-cast and aged conditions were determined. Tensile strength was found to increase with the addition of Bi. Additionally, alloys containing 2 and 3 wt.% Bi showed a 5 to 10% increase in tensile strength after isothermal aging of 90 days at 125 °C. On the contrary, the tensile strength of alloys with up to 1 wt.% Bi decreased by 22 to 48% after such aging. Using a Scanning Electron Microscope (SEM) and energy dispersive spectroscopy (EDS), the microstructure of the alloys was characterized. The aging-induced property changes in the samples were correlated to strengthening by Bi solute atoms for alloys with 1 wt.% Bi and the formation of Bi precipitation for alloys with 2 wt.% and 3 wt.% Bi. Full article

In directional forming processes, such as rolling and extrusion, the grains can develop preferred crystal orientations. These preferred orientations—the texture—are the main cause for material anisotropy. This anisotropy leads to phenomena such as earing, which occur during further forming processes, e.g., during the deep drawing of sheet metal. Considering anisotropic properties in numerical simulations allows us to investigate the effects of texture-dependent defects in forming processes and the development of possible solutions. Purely phenomenological models for modeling anisotropy work by fitting material parameters or applying measured anisotropy properties to all elements of the part, which remain constant over the duration of the simulation. In contrast, crystal plasticity methods, such as the visco-plastic self-consistent (VPSC) model, provide a deeper insight into the development of the material microstructure. By experimentally measuring the initial texture and using it as an initial condition for the simulations, it is possible to predict the evolution of the microstructure and the resulting effect on the mechanical properties during forming operations. The results of the simulations with the VPSC model show a good agreement with corresponding compression tests and the earing phenomenon, which is typical for cup deep drawing. Full article