修正GTN模型及其在预测硅钢冷轧边裂中的应用

考虑剪应变对微孔洞损伤演化的影响, 对GTN损伤模型的损伤演化机制进行修正, 建立了适用于不同应力三轴度水平的损伤模型. 结合隐式应力更新算法和显式有限元计算, 采用VUMAT子程序实现了修正GTN模型在有限元软件ABAQUS中的数值计算. 通过模拟纯剪切和剪切-拉伸两组试样的损伤演化和断裂行为, 验证了修正GTN模型在不同应力三轴度承载条件下的有效性. 运用修正GTN损伤模型模拟含边部缺口的带钢在轧制过程中裂纹的萌生和扩展行为, 模拟结果与实验相一致, 表明该模型可有效地用于带钢缺陷在轧制过程中扩展行为的分析和预测. 模拟和实验结果表明, 带钢边部缺口在轧制过程中, 缺口前沿和后沿均会萌生裂纹, 且后沿裂纹扩展更为明显.     

非线性路径下板料拉深成形过程中破裂预测

在优选模型参数和简化孔洞形核规律的基础上,采用Gurson-Tvergaard (GT) 多孔材料本构模型分析圆筒件拉深过程;根据金属成形工艺特点,综合考虑拉伸型和剪切型2种不同韧性断裂机制,提出一个统一的韧性断裂准则形式.对于未经过预变形和经过预变形的圆筒件拉深试验和数值模拟进行了比较,结果表明:相对于成形极限图,新的韧性断裂准则可以更加准确地预测非线性路径下圆筒件的拉深破裂.     

金属韧性断裂准则的数值模拟和试验研究

对不同外形的45钢试件进行了拉伸、压缩和扭转等材料试验,对工程中常用的5个韧性断裂准则的适用范围进行了对比研究,并采用Gurson-Tvergaard(GT)多孔材料本构模型对试验过程进行了数值模拟.指出目前使用的断裂准则都不可能对材料在多种变形条件下给出一个固定临界值.根据金属成形工艺特点,综合考虑拉伸型和剪切型2种不同韧性断裂机制,提出一个统一的韧性断裂准则形式.试验和数值计算结果证明了该准则的有效性和普适性,进而利用单向拉伸和扭转试验确定的材料常数合理地预测压缩过程中的韧性断裂现象.     

孔洞对铸造铝合金疲劳性能的影响

研究了铸造铝合金中孔洞在裂纹萌生、扩展过程中发挥的作用,孔洞的尺寸、体积分数、分布位置、形貌率等因素对材料的疲劳性能有重要影响.从试验现象和疲劳寿命模型两个方面综述了国内外学者研究的最新进展,指出了应力-寿命模型与线弹性断裂模型之间的内在联系,并讨论了存在的问题及研究方向.     

基于统计损伤理论的硫酸盐侵蚀混凝土本构模型研究

基于统计损伤理论及宏观试验现象,该文建立了考虑硫酸盐侵蚀影响的混凝土单轴、双轴压缩统计损伤本构模型。混凝土变形破坏被理解为细观断裂、屈服两种损伤模式的连续累积演化过程。硫酸盐侵蚀效应改变了混凝土微结构的组成成分和力学特征,进而改变了微裂纹萌生、扩展的形态以及损伤的累积演化过程,可通过改变断裂和屈服两种细观损伤机制演化过程的概率分布形态来模拟。分析结果表明：在硫酸盐侵蚀环境下,侵蚀程度的加深显著改变了混凝土细观损伤累积演化过程,最终导致混凝土宏观力学性能呈现先“强化”后“弱化”的现象。在此过程中,细观损伤演化过程呈现出明显地规律性,可由统计损伤模型中5个特征参数的变化规律表征。该文模型为复杂环境下侵蚀混凝土细观损伤过程预测和分析提供了新的方法和工具。     

孔洞敏感超塑性材料变形的数值分析

本文用两种数值方法,非线性长波分析和刚粘塑性有限元方法研究了孔洞敏感的超塑性材料在单向拉伸和园板涨形中的不均匀变形和断裂过程。分析表明,这种过程是不均匀几何失稳与内部孔洞长大的结合与相互作用的结果。材料的应变速率敏感性指数与孔洞长大速率通过不同的变形机理图控制着这种过程。叠加的静水压力能够改变孔洞敏感材料的断裂模式,从常压下没有宏观颈缩的孔洞断裂到无内部孔洞的外部颈缩断裂。     

基于I1断裂准则的圆棒试样单轴拉伸断裂过程分析

基于I₁断裂准则开展了两种材料模型圆棒试样单轴拉伸断裂过程的有限元模拟,结果表明：颈缩变形阶段,最小截面中心位置最先形成裂纹,在裂纹形成瞬间失稳扩展成一定尺寸的圆形裂纹后停止扩展,在后续持续增大的位移载荷作用下,裂纹步进式扩展;裂纹的形成与失稳扩展伴随着轴向作用力的急剧降低,利用该特征可测定材料的断裂强度I_b。     

高压水射流冲蚀混凝土破碎区演进特征及裂纹扩展规律研究

高压水射流冲击下混凝土内部裂纹扩展规律是洞察水力破碎机制的重要基础。借助相似材料、模型试验及高速摄像技术,构建了高压水射流冲击透明类混凝土冲蚀孔洞及裂纹扩展检测系统,研究了射流冲击混凝土冲蚀破碎区演化历程及裂纹扩展模式。结果表明,在射流冲击下混凝土破碎区演进过程分为三个典型阶段:水锤压缩区扩展、非压缩区扩展及侵彻贯通后扩展。在水锤压缩区冲蚀孔洞以近似"花瓣"状形态向自由面扩展,在冲蚀孔洞阵前面存在显著的塑性屈服区及交错裂纹网,并从理论上提出了冲蚀孔洞演进的临界判据;在非压缩区冲蚀孔洞近域塑性屈服区明显减少,材料去除演变为完全脆性破碎模式,冲蚀孔洞轴向演进速度呈现阶段性停滞;侵彻贯通后冲蚀孔洞径向维度将继续增大,并在孔壁近域出现不连续、半球状微裂纹区域,当扩展至初始贯通孔径2倍左右时,主冲蚀孔洞将趋于稳定。     

基于韧性准则的金属板料冲压成形断裂模拟

该文基于Rice-Tracey韧性失效准则,探索金属板料冲压成形的断裂数值模拟方法。首先设计两种试验,并结合有限元分析结果确定双相钢板料的材料失效参数;然后,基于Abaqus软件的显式模块Explicit,编写采用Rice-Tracey韧性失效准则的用户自定义材料子程序VUMAT;最后对双相钢薄板深拉成形过程中的断裂行为进行数值模拟,并进行了试验验证。结果表明,数值模拟结果与试验结果吻合较好。可见,Rice-Tracey韧性准则可用于金属板料冲压成形的断裂预测。     

基于能量的弹塑性损伤实用本构模型

建立一个实用的弹塑性损伤本构模型。在有效应力空间采用经验公式计算塑性变形,能将模型塑性部分与损伤部分解耦,降低模型的数值处理复杂性,同时大大简化模型塑性应变的计算。结合不可逆热力学理论,基于损伤能量释放率建立损伤准则,损伤能量释放率由修正后的弹性Helmholtz自由能导出,模型中将弹性Helmholtz自由能分解为应力球量部分和应力偏量部分,将其应力球量部分产生的损伤取为零,同时根据应力状态引入折减系数对其应力偏量部分进行修正,使得模型能较为准确的模拟混凝土材料在双轴加载下的本构行为。将应力张量谱分解为正、负两部分以分别定义材料受拉、受压损伤演化,并采用受拉损伤变量、受压损伤变量分别模拟混凝土材料在拉、压加载下的本构特性。引入一个加权损伤变量使得模型能较准确的反映混凝土材料的“拉-压软化效应”。最后该文给出初步试验验证,证明了该文模型的有效性。     

Growth and coalescence of penny-shaped voids in metallic alloys

The growth and coalescence of penny-shaped voids resulting from particle fracture is a common damage process for many metallic alloys. A three steps modeling strategy has been followed to investigate this specific failure process. Finite element cell calculations involving very flat voids shielded or not by a particle have been performed in order to enlighten the specific features of a damage mechanism starting with initially flat voids with respect to more rounded voids. An extended Gurson-type constitutive model supplemented by micromechanics-based criteria for both void nucleation and void coalescence is assessed for the limit of very flat voids towards the FE calculations. The constitutive model is then used to generate a parametric study of the effects of the stress state, the microstructure and the mechanical properties on the ductility. Based on these results, a simple closed-form model for the ductility is finally proposed. The main outcomes of this study are that (i) the ductility of metal alloys involving penny-shaped voids is primarily controlled by the relative void spacing; (ii) the definition of an effective porosity in terms of an equivalent population of spherical voids is valid for low particle volume fraction; (iii) the presence of a particle shielding the void does not significantly affect the void growth rates and void aspect evolution; (iv) early fracture by void coalescence can occur under very low stress triaxiality conditions if the particle volume fraction is large enough, explaining that some alloys and composites can fail through a transgranular ductile fracture mode under uniaxial tension condition before the onset of necking; (v) the fracture mechanism moves from void growth controlled to void nucleation controlled when increasing the void nucleation stress, lowering the stress triaxiality, and increasing the initial void aspect ratio.     

Investigation on fracture mechanisms of metals under various stress states

Fracture mechanisms for widely used metal materials are investigated under various loading conditions. Several specimens and different loading methods are deliberately designed to produce various stress states. The stress triaxiality is used to rate the level of tension and compression under various stress states. The stress triaxiality increases with adding a notch in the specimen under tension loading and decreases by changing the loading from tension to compression. Scanning electron microscopes are used to observe the microscopic features on the fracture surfaces. The fracture surfaces observed in the tests indicate that with the decreasing stress triaxiality the fracture mechanism for a given metal material includes intergranular cleavage, nucleation, growth, void coalescence, and local shear band expansion. With the fracture mechanisms changing from intergranular cleavage to nucleation, growth, and coalescence of voids, and expansion of a local shear band, four possible fracture modes can be observed, which are quasi-cleavage brittle fracture, normal fracture with void, shear fracture with void, and shear fracture without void. Quasi-cleavage brittle fracture and normal fracture with void are both normal stress-dominated fracture modes; however, their mechanisms are different. Shear fracture with and without void are both shear stress-dominated fracture, and shear fracture with void is also influenced by the normal stress. To a certain metal material, under high stress triaxiality, quasi-cleavage brittle fracture and normal fracture with void tend to occur, and under low stress triaxiality, shear fracture with and without void tend to occur. In addition, the critical positions and fracture criteria adapted to each fracture mode will also be different.     

Use of a modified Gurson model approach for the simulation of ductile fracture by growth and coalescence of microvoids under low, medium and high stress triaxiality loadings

In the paper the modified Gurson model is developed for the simulation of damage growth and ductile fracture under low, medium and high stress triaxiality loadings. A new coalescence criterion is introduced based on a simple assumption that singular value of the effective stress triggers the coalescence of microvoids in materials. According to the introduced approach the void coalescence described by means of the modified Gurson model is not only determined by the so-called critical, constant void volume fraction but also by the stress triaxiality ratio. Computational simulations have been carried out for Al 2024–T351 aluminum specimens. In order to find some improvements of micromechanical damage models, two different approaches have been compared for modeling the shear driven microvoid coalescence under low stress triaxiality loadings.     

Stress triaxiality effect on void nucleation in ductile metals

The stress triaxiality effect on the strain required for void nucleation by particle‐matrix debonding has been investigated by means of micromechanical modelling. A unit‐cell model considering an elastic spherical particle embedded in an elastic‐plastic matrix was developed to the purpose. Particle‐matrix decohesion was simulated through the progressive failure of a cohesive interface. It has been shown that the parameters of matrix‐particle cohesive interface are correlated with macroscopic material properties. Here, a simple relationship for the maximum cohesive opening at interface failure as a function of material fracture toughness and yield stress has been derived. Results seem to confirm that, increasing stress triaxiality, the strain at which void nucleation is predicted to occur decreases exponentially in a similar way as for fracture strain. This result has substantial implications in modelling of ductile damage because it indicates that if the stress triaxiality is high enough, ductile fracture can occur at plastic strain lower than that necessary to nucleate damage for moderate or low stress triaxiality regime.     

A modified Gurson model and its application to punch-out experiments

Recent experimental evidence has reiterated that ductile fracture is a strong function of stress triaxiality. Under high stress triaxiality loading, failure occurs as a result of void growth and subsequent necking of inter-void ligaments while under low stress triaxiality failure is driven by shear localization of plastic strain in these ligaments due to void rotation and distortion. The original Gurson model is unable to capture localization and fracture for low triaxiality, shear-dominated deformations unless void nucleation is invoked. A phenomenological modification to the Gurson model that incorporates damage accumulation under shearing has been proposed. Here we further extend the model and develop the corresponding numerical implementation method. Several benchmark tests are performed in order to verify the code. Finally, the model is utilized to model quasi-static punch-out experiments on DH36 steel. It is shown that the proposed modified Gurson model, in contrast to the original model, is able to capture the through-thickness development of cracks as well as the punch response. Thus, the computational fracture approaches based on the modified Gurson model may be applied to shear-dominated failures.     

Continuum damage mechanics modelling incorporating stress triaxiality effect on ductile damage initiation

Micromechanical modelling of void nucleation in ductile metals indicates that strain required for damage initiation reduces exponentially with increasing stress triaxiality. This feature has been incorporated in a continuum damage mechanics (CDM) model, providing a phenomenological relationship for the damage threshold strain dependence on the stress triaxiality. The main consequences of this model modification are that the failure locus is predicted to change as function of stress triaxiality sensitivity of the material damage threshold strain and that high triaxial fracture strain is expected to be even lower than the threshold strain at which the damage processes initiate at triaxiality as low as 1/3. The proposed damage model formulation has been used to predict ductile fracture in unnotched and notched bars in tension for two commercially pure α‐iron grades (Swedish and ARMCO iron). Finally, the model has been validated, predicting spall fracture in a plate‐impact experiment and confirming the capability to capture the effect of the stress state on material fracture ductility at very high stress triaxiality.     

Stress state dependent fracture behaviour of porous PM steels

Ductile fracture of metals is a result of void nucleation, growth and coalescence. Various criteria have been proposed to model the ductile fracture strain as a function of the stress triaxiality that greatly influence the fracture process. In the present investigation, the well-known Rice and Tracey approach (with a re-evaluation conducted by Huang) was used to model the ductile fracture behaviour of two porous steels, produced by Powder Metallurgy (PM): a ferritic–pearlitic Fe–0.4%C PM steel and a high-strength steel produced by using diffusion-alloyed Fe–4%Ni–1.5%Cu–0.5%Mo–0.5%C powder. Tensile, compressive and bending tests were carried on un-notched and notched specimens. The experimental curves were used as a reference for the Finite Element (FE) modeling of the tests aimed at evaluating the equivalent fracture strain at fracture and the correspondent stress triaxiality for each geometry. The results obtained for the Fe–0.4%C PM steel proved the suitability of the modified Rice and Tracey relationship to successfully obtain a simple fracture criterion. However, in the case of high-strength steel, a mixed ductile/brittle fracture behaviour was observed because of the microstructural heterogeneity of the alloy. Because of this, the Rice and Tracey model overestimates the experimental equivalent fracture strains and has to be accordingly corrected.     

Fracture Criteria for Automobile Crashworthiness Simulation of Wrought Aluminium Alloy Components

In automobile crashworthiness simulation, the prediction of plastic deformation and fracture of each significant, single component is critical to correctly represent the transient energy absorption through the car structure. There is currently a need, in the commercial FEM community, for validated material fracture models which adequately represent this phenomenon. The aim of this paper is to compare and to validate existing numerical approaches to predict failure with test data. All studies presented in this paper were carried out on aluminium wrought alloys: AlMgSi1.F31 and AlMgSiCu‐T6. A viscoplastic material law, whose parameters are derived from uniaxial tensile and compression tests at various strain rates, is developed and presented herein. Fundamental ductile fracture mechanisms such as void nucleation, void growth, and void coalescence as well as shear band fracture are present in the tested samples and taken into consideration in the development of the fracture model. Two approaches to the prediction of fracture initiation are compared. The first is based on failure curves expressed by instantaneous macroscopic stresses and strains (i. e. maximum equivalent plastic strain vs. stress triaxiality). The second approach is based on the modified Gurson model and uses state variables at the mesoscopic scale (i. e. critical void volume fraction). Notched tensile specimens with varying notch radii and axisymmetric shear specimens were used to produce ductile fractures and shear band fractures at different stress states. The critical macroscopic and mesoscopic damage values at the fracture initiation locations were evaluated using FEM simulations of the different specimens. The derived fracture criteria (macroscopic and mesoscopic) were applied to crashworthiness experiments with real components. The quality of the prediction on component level is discussed for both types of criteria.     

On the Effect of Stress Triaxiality on Void Coalescence

Failure of ductile materials is often related to coalescence of microscopic voids. The stress triaxiality is one of the primary factors that influence the coalescence. In the present work, a 3D unit cell model is employed to investigate this effect. The cell model contains two aligned voids. A coalescence criterion is proposed in which the critical void volume fraction is expressed in terms of stress triaxiality.     

一种韧性断裂模型的理论研究和实验验证

为研究高强钢板成形过程中的损伤破裂机理,更准确地预测高强钢的断裂失效行为,基于细观损伤力学的空穴理论,并在屈服函数就是塑性势函数的通用性假设基础上推导了各向同性的韧性断裂模型;同时引入Lode参数以反映不同应变状态下空穴形核、长大以及聚合的差异,提出了一种包含应力三轴度和Lode参数的新模型.在Hill正交各向异性屈服假设下,描述了平面应力状态下应力比值、r值与应力三轴度、等效塑性应变的关系.最后,针对DP590进行了参数确定和实验验证.结果表明:应力三轴度在高强钢韧性断裂中仍然起主导因素,在低应力三轴下,材料主要是剪切型破坏,空穴的长大及聚合方式主要受剪应力影响,高应力三轴下,空穴损伤主要受拉应力影响,断裂是韧窝形的;Lode参数决定了应力组成形式,也间接地反映了应变状态,它与应力三轴度共同决定了空穴损伤的发展.新的模型能较准确地预测DP590的成形极限.