Ductile fracture prediction in cold forging process chains

The paper presents a new approach for the prediction of ductile fracture occurrence in multi-stage cold forging process chains. The approach combines the fracture criterion proposed by Xue and Wierzbicky with a linear damage accumulation law. Thanks to this feature, the approach is capable of predicting both the location where the failure events occur under the action of external loading and the time they take to be generated. An application to the multi-stage cold forging of a C35 Torx-type socket screw carried out on a double-blow header is presented and results of predictions are compared with experimental observations.     

Damage characterization in non-isothermal stretching of acrylics. Part I: Theory

An improved version of dual-mechanism constitutive model was proposed to describe thermo-mechanical response of amorphous polymers below and above glass transition temperature (θ_g). Material property definitions and plastic flow rules were revisited to provide a smooth and continuous transition in material response around θ_g. The elastic-viscoplastic constitutive model was developed based on thermodynamics framework and was implemented in a fully coupled thermo-mechanical simulation of non-isothermal testing of PMMA in Part II [Gunel, E. M., Basaran, C., 2010. Damage characterization in non-isothermal stretching of acrylics. Part II: Experimental validation. Mechanics of Materials]. For damage evolution in complex thermo-mechanical problems such as polymer processing operation, irreversible entropy production was considered as the measure of damage.     

Damage characterization in non-isothermal stretching of acrylics. Part II: Experimental validation

Influence of temperature and strain rate on damage accumulation and large deformation behavior of acrylics was investigated under conditions similar to actual polymer processing. Poly(methyl methacrylate) (PMMA) samples were stretched to large strains at different rates under transient thermal conditions. During testing, specimens were cooled down from temperatures above glass transition temperature (θ_g) to temperatures well-below θ_g inducing a transition from rubbery state to solid state. Contrary to common practice of studying thermo-mechanical coupling in terms of adiabatic heating; in proposed experimental study, temperature effect on mechanical response of material was emphasized by externally intervening temperature variation within specimen. An improved version of dual-mechanism constitutive model presented in Part I [Gunel, E.M., Basaran, C., 2010. Damage characterization in non-isothermal stretching of acrylics. Part I: Theory. Mechanics of Materials] was proposed to predict thermo-mechanical response of amorphous polymer below and above θ_g. Applicability of proposed constitutive model for the specific case of non-isothermal stretching of PMMA at different test conditions was demonstrated by incorporating it into a finite element scheme. Constitutive model was reasonably accurate to capture observed temperature-displacement-force history in experimental study. Damage evolution under different testing conditions was studied in terms of irreversible thermal and mechanical entropy production.     

Tensile behaviour of patch-repaired CFRP laminates

The present study examines the tensile behaviour of composite structures repaired by bonding external patches. Various patches of different stacking sequences placed on both sides of the parent plate were considered. Damage development and the failure process of the repaired plates were analyzed and a parent plate fracture model has been proposed. Optimised patch repairs were calculated by finite element modelling. It was found that high stress concentration along the longitudinal edges of circular patches and/or at the transverse edges of the hole leads to early damage initiation in the parent plate. However, the position of damage initiation and the process of damage progression depend particularly on the properties of repair patches. In order to optimise patch repairs, finite element modelling was used and it was founded possible to attain over 90% of the strength of an unnotched specimen. The optimised patch design can be characterised by an optimal strength ratio R^*, which should be minimized when selecting repair parameters.     

Investigation on the compressive properties of the three dimensional four-directional braided composites

The compressive mechanical properties of three dimensional (3D) braided composites are of key concern for design in actual engineering application. A representative volume cell (RVC) is chosen to study the uniaxial compressive mechanical properties of the braided composites with different braid angles by combing damage theory and finite element method. The fiber misalignment and longitudinal shear nonlinearity of braid yarn are considered in the computation model. And their influences on the compressive behavior of the braided composites are also evaluated. The damage development of constituents within the braided composites are obtained and analyzed. The main damage and failure modes and their interaction of braid yarn are provided as well. The numerical results are found that the compressive mechanical behavior of the braided composites with lower braid angle is sensitive to the fiber initial imperfection of braid yarn. The strength of the braided composites with different braid angle is controlled by the different microscopic failure modes.     

Numerical analysis of intralaminar failure mechanisms in composite structures. Part I: FE implementation

This paper presents a three-dimensional continuum damage mechanics-based material model which was implemented in an implicit finite element code to simulate the progressive intralaminar degradation of fibre reinforced laminates. The damage model is based on ply failure mechanisms and uses seven damage variables assigned to tensile, compressive and shear damage at a ply level. Non-linear behaviour and irreversibility were taken into account and modelled. Some issues on the numerical implementation of the damage model are discussed and solutions proposed. Applications of the methodology are presented in Part II [1].     

ESEM investigations for assessment of damage kinetics of short glass fibre reinforced thermoplastics - Results of in situ tensile tests coupled with acoustic emission analysis

The damage mechanisms of short glass fibre reinforced polypropylene (PP) and polybutene-1 (PB-1) materials were investigated. For this purpose, in situ tensile tests were conducted in the environmental scanning electron microscope (ESEM) while simultaneously recording the acoustic emission (AE). To be able to observe damage mechanisms directly during loading, notched specimens were used. This method allows the direct correlation of the recorded load - elongation data with observed damage mechanisms, as well as correlations with acoustic emission data. Hence, it is possible to describe the damage kinetics of short glass fibre composite.It was found that different bonding conditions of the two investigated materials result in different damage mechanisms as well as in different AE behaviour. For fibre reinforced PP with excellent bonding conditions of the fibres in the polymeric matrix, fibre fracture, slipping of fibres in the delamination area, debonding and pull-out with matrix yielding was observed. The determined AE parameter amplitude A_p and energy E_AE for the PB-1 material are lower because of the weak bonding of the fibres to the PB-1-matrix. Hence, energy dissipative damage mechanisms like pull-out with matrix yielding can occur only in a limited part of such materials.     

Hierarchical composites: Analysis of damage evolution based on fiber bundle model

A computational model of multiscale composites is developed on the basis of the fiber bundle model with the hierarchical load sharing rule, and employed to study the effect of the microstructures of hierarchical composites on their damage resistance. Two types of hierarchical materials were considered: “hierarchical tree” (bundles-of-bundles of fibers) and self-similar particle and fiber reinforced composite (in which reinforcements at each scale level represents composites in turn consisting of lower level reinforcements and matrix). For the case of the hierarchical tree (“bundle-of-bundles” material), it was observed that the increase in the amount of hierarchy levels leads to the lower strength of material. In the self-similar fiber reinforced matrix materials, as differed from the hierarchical trees, the damage resistance of the hierarchical materials increases with increasing the amount of hierarchy levels. The effect of mixed fiber and particle reinforcement on the damage resistance of the hierarchical composites is investigated as well.     

Analysing and modelling the 3D shear damage behaviour of hybrid yarn textile-reinforced thermoplastic composites

The presented work focuses on the examination of the 3D shear damage behaviour and its phenomenological failure process of a thermoplastic composite made of E-glass/polypropylene hybrid yarn with a woven reinforcement. Experimental shear characterisation is performed by means of the Iosipescu testing approach for both in-plane and through-thickness directions. A procedure for the manufacturing of through-thickness shear specimens is presented in this study. The characterisation of the chronological failure process and deformation analysis is supported by high speed camera system and Digital Image Correlation. Based on the experimental observations, material modelling strategies are derived and performed within the finite element environment Ls-Dyna.     

An experimental investigation on the low velocity impact response of composite plates repaired by VARIM and hand lay-up processes

This paper presents results of an experimental investigation on the impact response of repaired and unrepaired glass/epoxy composite plates. Repaired samples were prepared by two different manufacturing methods; vacuum assisted resin infusion process and hand lay-up technique. In order to compare impact response of the repaired and unrepaired samples a number of single impact tests were performed under various impact energies. Damage process of the samples is analyzed from cross-examining load–deflection curves and damaged specimens. From the visual inspection, for the impacted side of the samples, it is noted that the main damage modes for repaired samples are matrix and fiber cracks around point of impact and delaminations while severe matrix cracks expanded through fiber directions are the dominant damage mode for unrepaired samples. At the back surfaces, delaminations and fiber–matrix debonding oriented in the fiber directions are observed for unrepaired samples. However, for repaired samples the fiber fractures through repair line as well as the delaminations become dominant modes. For a reasoning justification in discussing impact test results, interlaminar fracture toughness (Mode I and Mode II) and flexural tests for repaired and non-repaired samples were also conducted.