An integrated continuous-discontinuous approach towards damage engineering in sheet metal forming processes

This paper addresses the simulation of ductile damage and fracture in metal forming processes. A combined continuous-discontinuous approach has been used, which accounts for the interaction between macroscopic cracks and the surrounding softening material. Softening originates from the degradation processes taking place at a microscopic level, and is modelled using continuum damage mechanics concepts. To avoid pathological localisation and mesh dependence and to incorporate length scale effects due to microstructure evolution, the damage growth is driven by a non-local variable via a second order partial differential equation. The two governing equations, i.e. equilibrium and non-local averaging, are solved in an operator-split manner. This allows one to use a commercial finite element software to solve the equilibrium problem, including contact between the tools and work piece. The non-local averaging equation is solved on a fixed configuration, through a special purpose code which interacts with the commercial code. A remeshing strategy has been devised that allows: (i) to capture the localisation zone, (ii) prevent large element distortions and (iii) accommodate the crack propagation. To illustrate the capabilities of the modelling tool obtained by combining these continuum mechanics concepts and computational techniques, process simulations of blanking, fine-blanking and score forming are presented.     

A concurrent atomistic and continuum coupling method with applications to thermo‐mechanical problems

We present a novel method to couple molecular dynamics with finite elements at finite temperatures using spatial filters. The mismatch in the dispersion relations between continuum and atomistic models leads, at finite temperature, to unwanted mesh vibrations, which are illustrated using a standard least square coupling formulation. We propose the use of spatial filters with the least square minimization to selectively damp the unwanted mesh vibrations. Then, we extend the idea of selective damping of wavelength modes to couple atomistic and continuum models at finite temperatures. The restitution force from the generalized Langevin equation is modified to perform a two‐way thermal coupling between the two models. Three different numerical examples are shown to validate the proposed coupling formulation in two‐dimensional space. Finally, the method is applied to a high‐speed impact simulation. Copyright © 2013 John Wiley & Sons, Ltd.     

Damage driven crack initiation and propagation in ductile metals using XFEM

Originally Continuum Damage Mechanics and Fracture Mechanics evolved separately. However, when it comes to ductile fracture, an unified approach is quite beneficial for an accurate modelling of this phenomenon. Ductile materials may undergo moderate to large plastic deformations and internal degradation phenomena which are well described by continuum theories. Nevertheless in the final stages of failure, a discontinuous methodology is essential to represent surface decohesion and macro-crack propagation. In this work, XFEM is combined with the Lemaitre ductile damage model in a way that crack initiation and propagation are governed by the evolution of damage. The model was built under a finite strain assumption and a non-local integral formulation is applied to avoid pathological mesh dependence. The efficiency of the proposed methodology is evaluated through various numerical examples.     

A new eight-node quadrilateral shear-bending plate finite element

A new eight-node quadrilateral shear-bending Reissner–Mindlin plate finite element for the very thin and thick plates without locking and spurious zero-energy modes is presented. The element has very good convergence characteristics both for thin and thick plates, is hardly insensitive to mesh distortions, and passes the patch tests. The formulation of the element is derived from a displacement variational principle and some general criteria to compute inconsistent transverse shear strains. These criteria have been applied with success to four- and eight-node quadrilateral plate finite elements and could be applied to construct triangular elements. The eight-node quadrilateral shear-bending plate finite element proposed has been found to be very efficient.     

Arbitrary Lagrangian–Eulerian finite element analysis of strain localization in transient problems

Non-local models guaranty that finite element computations on strain softening materials remain sound up to failure from a theoretical and computational viewpoint. The non-locality prevents strain localization with zero global dissipation of energy, and consequently finite element calculations converge upon mesh refinements to non-zero width localization zones. One of the major drawbacks of these models is that the element size needed in order to capture the localization zone must be smaller than the internal length. Hence, the total number of degrees of freedom becomes rapidly prohibitive for most engineering applications and there is an obvious need for mesh adaptivity. This paper deals with the application of the arbitrary Lagrangian–Eulerian (ALE) formulation, well known in hydrodynamics and fluid–structure interaction problems, to transient strain localization in a non-local damageable material. It is shown that the ALE formulation which is employed in large boundary motion problems can also be well suited for non-linear transient analysis of softening materials where localization bands appear. The remeshing strategy is based on the equidistribution of an indicator that quantifies the interelement jump of a selected state variable. Two well known one-dimensional examples illustrate the capabilities of this technique: the first one deals with localization due to a propagating wave in a bar, and the second one studies the wave propagation in a hollow sphere.     

Ductile damage modelling with locking‐free regularised GTN model

The major goal of this work is to develop a robust modelling strategy for the simulation of ductile damage development including crack initiation and subsequent propagation. For that purpose, a Gurson‐type model is used. This model class, as many other damage models, leads to significant material softening and must be used within a large deformation framework due to the ductile character of the materials. This leads to 2 main difficulties that should be dealt with carefully: mesh dependency and volumetric locking. In this work, a logarithmic finite strain framework is adopted in which the Gurson‐Tvergaard‐Needleman constitutive law is reformulated. Then a nonlocal formulation with regularisation of hardening variable is applied so as to solve mesh dependency and strain localization problem. In addition, the nonlocal model is combined with mixed “displacement‐pressure‐volume variation” elements to avoid volumetric locking. Thereby, a mesh‐independent and locking‐free finite strain framework suitable for the modelling of ductile rupture is established. Attention is paid to mathematical properties and numerical performance of the model. Finally, the model parameters are identified on an experimental database for a nuclear piping steel. Simulations of standard test specimens (notched tensile bars and compact tension and single edge notched tensile cracked specimens) are performed and compared to experimental results.     

Artificial adjustment of element stiffness with a particular reference to plate bending

A finite element may satisfy all convergence requirements and work well except for being too stiff or too flexible when the mesh is coarse. Here we discuss a technique for softening or stiffening such elements, provided that they have internal degrees-of-freedom. The technique is applied to a previously derived plate element, and the element is found to be much improved.     

A mixed finite element and mesh-free method using linear complementarity theory for gradient plasticity

A mixed finite element (FE) and mesh-free (MF) method for gradient-dependent plasticity using linear complementarity theory is presented. The assumed displacement field is interpolated in terms of its discrete values defined at the nodal points of the FE mesh with the FE shape functions, whereas the assumed plastic multiplier field required to express its Laplacian is interpolated in terms of its discrete values defined at the integration points of the FE mesh with the MF interpolation functions. A standard form of linear complementarity problem is constructed by combining the weak form of momentum conservation equation and pointwise enforcements of both non-local constitutive equation and non-local yield criterion. The discrete values of the plastic multiplier are taken as the only primary unknowns to be determined. The numerical results demonstrate the validity of the proposed method in the simulation of the strain localization phenomenon due to strain softening.     

Polynomial approximation of shape function gradients from element geometries

A method is presented for the polynomial approximation of shape function gradients based solely on the geometry of finite element boundaries. The method is founded on a least squares approach which leads to an integration scheme satisfying a necessary condition for convergence. In its simplest form the method reduces to the well‐known uniform strain approach for finite elements. The method is applicable to a broad class of problems such as connecting dissimilar meshes, mesh adaptivity and transitioning, and the construction of finite elements with variable topologies. Finite elements based on the polynomial approximations are shown to pass patch tests of various orders. In contrast to standard elements, higher‐order patch tests are passed without the need for nodes internal to element boundaries. Less sensitivity to volumetric locking under plane strain conditions is demonstrated through comparisons with a standard element formulation. Copyright © 2001 John Wiley & Sons, Ltd.     

3D modelling of strong discontinuities in elastoplastic solids: fixed and rotating localization formulations

This paper is concerned with the incorporation of displacement discontinuities into a continuum theory of elastoplasticity for the modelling of localization processes such as cracking in brittle materials. Based on the strong discontinuity approach (SDA) (Computational Mechanics 1993; 12: 277–296) mesh objective 2D and 3D finite element formulations are developed using linear and quadratic 2D elements as well as 8‐noded 3D elements. In the formulation of the finite‐element model proposed in the paper, the analogy with standard formulations is emphasized. The parameter defining the amplitude of the displacement jump within the finite element is condensed out at the material level without employing the standard static condensation technique. This approach results in linearized constitutive equations formally identical to continuum models. Therefore, the standard return mapping algorithm is used to solve the non‐linear equations. In analogy to concepts used in continuum smeared crack models, a rotating formulation of the SDA is proposed in addition to the standard concept of fixed discontinuities. It is shown that the rotating localization approach reduces locking effects observed in analyses based on fixed localization directions. The applicability of the proposed SDA finite‐element model as well as its numerical performance is investigated by means of a three‐dimensional ultimate load analysis of a steel anchor embedded in a concrete block subjected to a shear force. Copyright © 2003 John Wiley & Sons, Ltd.     

Mesh motion techniques for the ALE formulation in 3D large deformation problems

Efficient mesh motion techniques are a key issue to achieve satisfactory results in the arbitrary Lagrangian–Eulerian (ALE) finite element formulation when simulating large deformation problems such as metal‐forming. In the updated Lagrangian (UL) formulation, mesh and material movement are attached and an excessive mesh distortion usually appears. By uncoupling mesh movement from material movement, the ALE formulation can relocate the mesh to avoid distortion. To facilitate the calculation process, the ALE operator is split into two steps at each analysis time step: UL step (where deformation due to loading is calculated without convective terms) and Eulerian step (where mesh motion is applied). In this work, mesh motion is performed by new nodal relocation methods, developed for eight‐node hexahedral elements, which can move internal and boundary nodes, improving and concentrating the mesh in critical zones. After mesh motion, data is transferred from the UL mesh to the relocated mesh using an expansion of stresses in a Taylor's series. Two numerical applications are presented, comparing results of UL and ALE formulation with results found in the literature. Copyright © 2004 John Wiley & Sons, Ltd.     

A physically and geometrically nonlinear scaled‐boundary‐based finite element formulation for fracture in elastomers

This paper is devoted to the formulation of a plane scaled boundary finite element with initially constant thickness for physically and geometrically nonlinear material behavior. Special two‐dimensional element shape functions are derived by using the analytical displacement solution of the standard scaled boundary finite element method, which is originally based on linear material behavior and small strains. These 2D shape functions can be constructed for an arbitrary number of element nodes and allow to capture singularities (e.g., at a plane crack tip) analytically, without extensive mesh refinement. Mapping these proposed 2D shape functions to the 3D case, a formulation that is compatible with standard finite elements is obtained. The resulting physically and geometrically nonlinear scaled boundary finite element formulation is implemented into the framework of the finite element method for bounded plane domains with and without geometrical singularities. The numerical realization is shown in detail. To represent the physically and geometrically nonlinear material and structural behavior of elastomer specimens, the extended tube model and the Yeoh model are used. Numerical studies on the convergence behavior and comparisons with standard Q1P0 finite elements demonstrate the correct implementation and the advantages of the developed scaled boundary finite element. Copyright © 2014 John Wiley & Sons, Ltd.     

Simulating the propagation of displacement discontinuities in a regularized strain‐softening medium

A numerical model is developed which allows the inclusion of displacement discontinuities in a strain‐softening medium, independent of the finite element mesh structure. Inelastic deformations develop in the continuum and, when a critical threshold of inelastic deformation is reached, a displacement discontinuity is inserted. Discontinuities are introduced using the partition of unity concept which allows discontinuous functions to be added to the standard finite element basis. It is shown that the introduction of displacement discontinuities at the later stages of the failure process can lead to a failure mode that is fundamentally different than that using a continuum model only. This combined continuum‐discontinuous model is better able to describe the entire failure process than a continuum or a discrete model alone and treats mode‐I and mode‐II failure in a unified fashion. Copyright © 2001 John Wiley & Sons, Ltd.     

A Pian–Sumihara type element for modeling shear bands at finite deformation

A monolithic numerical solution of a partial differential equation (PDE) model for shear bands, which includes a thermal softening rate dependent plastic flow rule and finite thermal conductivity, is presented. The formulation accounts for large deformation kinematics and includes incrementally objective treatment of the hypoplastic constitutive relations. Regularization is achieved by including finite thermal conductivity, which informs the PDE system of a length scale, governed by competition between shear heating and thermal diffusion. The monolithic solution scheme is then used to eliminate splitting errors during the solution of the discretized system. The scheme is presented in a general, mixed formulation, which allows for many choices of shape functions. We study and compare two elements, which have been implemented with the monolithic nonlinear solver: the Irreducible Shear Band Quad (ISBQ) and the Pian Sumihara Shear Band Quad (PSSBQ). ISBQ employs the same interpolation as an irreducible four node quad while PSSBQ is a mixed, assumed stress element. The algorithmic approximations to the Lie derivative and Jaumann rate of Kirchhoff stress are available in the literature for ISBQ type elements, and are derived in this paper for the PSSBQ. These expressions are used to achieve an incrementally objective formulation. It is found that the PSSBQ converges faster than the ISBQ with mesh refinement, and that the convergence of the ISBQ can be improved with a remeshing procedure.     

A framework for cohesive element enrichment

It was shown in a previous work by the same authors that the stringent mesh size requirement on cohesive, interface elements, can be alleviated through enrichment of the finite element basis functions. In this paper, some limitations of the enriched formulation are discussed and a new maximum mesh size requirement is established. The enriched formulation is also applied here to the simulation of mixed-mode delamination for the first time.     

A formulation for frictionless contact problems using a weak form introduced by Nitsche

In this paper a finite element formulation for frictionless contact problems with non-matching meshes in the contact interface is presented. It is based on a non-standard variational formulation due to Nitsche and leads to a matrix formulation in the primary variables. The method modifies the unconstrained functional by adding extra terms and a stabilization which is related to the classical penalty method. These new terms are characterized by the presence of contact forces that are computed from the stresses in the continuum elements. They can be seen as a sort of Lagrangian-type contributions. Due to the computation of the contact forces from the continuum elements, some additional degrees-of-freedom are involved in the stiffness matrix parts related to contact. These degrees-of-freedom are associated with nodes not belonging to the contact surfaces.     

An energy-stable mixed formulation for isogeometric analysis of incompressible hyperelastodynamics

We develop a mixed formulation for incompressible hyperelastodynamics based on a continuum modeling framework recently developed in the work of Liu and Marsden and smooth generalizations of the Taylor-Hood element based on nonuniform rational B-splines (NURBSs). This continuum formulation draws a link between computational fluid dynamics and computational solid dynamics. This link inspires an energy stability estimate for the spatial discretization, which favorably distinguishes the formulation from the conventional mixed formulations for finite elasticity. The inf-sup condition is utilized to provide a bound for the pressure field. The generalized-α method is applied for temporal discretization, and a nested block preconditioner is invoked for the solution procedure. The inf-sup stability for different pairs of NURBS elements is elucidated through numerical assessment. The convergence rate of the proposed formulation with various combinations of mixed elements is examined by the manufactured solution method. The numerical scheme is also examined under compressive and tensile loads for isotropic and anisotropic hyperelastic materials. Finally, a suite of dynamic problems is numerically studied to corroborate the stability and conservation properties.     

Novel quadratic Bézier triangular and tetrahedral elements using existing mesh generators: Applications to linear nearly incompressible elastostatics and implicit and explicit elastodynamics

In this paper, we present novel techniques of using quadratic Bézier triangular and tetrahedral elements for elastostatic and implicit/explicit elastodynamic simulations involving nearly incompressible linear elastic materials. A simple linear mapping is proposed for developing finite element meshes with quadratic Bézier triangular/tetrahedral elements from the corresponding quadratic Lagrange elements that can be easily generated using the existing mesh generators. Numerical issues arising in the case of nearly incompressible materials are addressed using the consistent B -bar formulation, thus reducing the finite element formulation to one consisting only of displacements. The higher-order spatial discretization and the nonnegative nature of Bernstein polynomials are shown to yield significant computational benefits. The optimal spatial convergence of the B -bar formulation for the quadratic triangular and tetrahedral elements is demonstrated by computing error norms in displacement and stresses. The applicability and computational efficiency of the proposed elements for elastodynamic simulations are demonstrated by studying several numerical examples involving real-world geometries with complex features. Numerical results obtained with the standard linear triangular and tetrahedral elements are also presented for comparison.     

A mixed finite element for the nonlinear analysis of in-plane loaded masonry walls

A mixed membrane eight-node quadrilateral finite element for the analysis of masonry walls is presented. Assuming that a nonlinear and history-dependent 2D stress-strain constitutive law is used to model masonry material, the element derivation is based on a Hu-Washizu variational statement, involving displacement, strain, and stress fields as primary variables. As the behavior of masonry structures is often characterized by strain localization phenomena, due to strain softening at material level, a discontinuous, piecewise constant interpolation of the strain field is considered at element level, to capture highly nonlinear strain spatial distributions also within finite elements. Newton's method of solution is adopted for the element state determination problem. For avoiding pathological sensitivity to the finite element mesh, a novel algorithm is proposed to perform an integral-type nonlocal regularization of the constitutive equations in the present mixed formulation. By the comparison with competing serendipity displacement-based formulation, numerical simulations prove high performances of the proposed finite element, especially when coarse meshes are adopted.