Numerical modelling of magnesium die-castings using stochastic fracture parameters

Quasi-static material tests using specimens cut from a generic cast component are performed to study the behaviour of the high-pressure die-cast magnesium alloy AM60 under different stress states. The experimental data set is applied to establish a validated probabilistic methodology for finite element modelling of thin-walled die-castings subjected to quasi-static loading. The test specimens are modelled in the explicit finite element (FE) code LS-DYNA using shell elements. The cast magnesium alloy AM60 is modelled using an elasto-plastic constitutive model including a high-exponent, isotropic yield criterion, the associated flow law and isotropic hardening. To simulate fracture, the Cockcroft-Latham fracture criterion is adopted, and the fracture parameter is chosen to follow a modified weakest-link Weibull distribution. Comparison between the experimental and predicted behaviour of the cast magnesium specimens gives very promising results.     

Quasi-static perforation of thin aluminium plates

This paper presents an experimental and numerical investigation on the quasi-static perforation of aluminium plates. In the tests, square plates were mounted in a circular frame and penetrated by a cylindrical punch. A full factorial design was used to investigate the effects of varying plate thickness, boundary conditions, punch diameter and nose shape. Based on the results obtained, both the main and interaction effects on the maximum force, displacement at fracture and energy absorption until perforation were determined. The perforation process was then computer analysed using the nonlinear finite element code LS-DYNA. Simulations with axisymmetric elements, brick elements and shell elements were conducted. Quasi-static, isothermal versions of the Johnson–Cook constitutive relation and fracture criterion were used to model the material behaviour. Good qualitative agreement was in general found between the experimental results and the numerical simulations. However, some quantitative differences were observed, and the reasons for these are discussed.     

Progressive crushing of fiber-reinforced composite structural components of a Formula One racing car

The present paper describes an experimental and numerical investigation on energy absorbers for Formula One side impact and steering column impact. The crash tests are performed measuring the load-shortening diagram and the energy absorbed by the structure. A finite element model is then developed using the non-linear, explicit dynamic code LS-DYNA. To set up the numerical model, tubes crushing testing are conducted to determine the material failure modes and to characterise them with LS-DYNA. The results presented in this study show that the composite structural components of the investigated Formula One racing car possess high value of specific absorbed energy and crash load efficiency around 1.1. The finite element simulations accurately predict the overall shape, magnitude and pulse duration in all the types of impact as well as the deformation and failure of the structures. Comparing the numerical data of the specific absorbed energy to the experimental results, the differences are around 10%.     

Aluminum alloy damage evolution for different strain paths - Application to hemming process

This work deals with ductile damage characterization of a 6000 series aluminum alloy. Tensile tests on both straight and notched samples at different orientations to the rolling direction, and equibiaxial expansion tests are performed up to fracture. The Gurson-Tvergaard-Needleman model, extended to the case of plastic anisotropy described by Hill’s 1948 yield criterion, is used to represent the material behavior. The parameters are identified by inverse analysis and by using finite element simulations for inhomogeneous tests. The coalescence criterion proposed by Tvergaard and Needleman is considered and a critical void volume fraction is then determined. The numerical simulation of a three-step hemming process of flat surface-straight edge sample is then performed, to investigate the influence of some process parameters on the damage development in the folded zone and thus to predict hemming limits.     

蜂窝夹层共形承载天线结构的力电性能

本文对玻璃钢蜂窝夹层共形承载天线结构进行常温四点弯曲试验,并对比了含有真实天线的实验件在实验前后的电磁性能。采用三明治夹芯板理论和分离式实体建模方法,利用ABAQUS建立其有限元模型,并基于各向异性材料最大应力准则,使用USDFLD定义蜂窝芯失效准则。实验和模拟结果表明:此方法能准确地模拟结构的刚度和强度。性能检测显示实验件能够承受预定载荷,从而验证了此类结构在弯曲载荷下的可靠性以及模拟方法的准确性。     

On the influence of constitutive relation in projectile impact of steel plates

In this paper the influence of constitutive relation has been studied in numerical simulations of the perforation of 12-mm thick Weldox 460 E steel plates impacted by blunt-nosed projectiles in the sub-ordinance velocity regime. A modified version of the well-known and much used constitutive relation proposed by Johnson-Cook and both the bcc- and hcp-version of the Zerilli-Armstrong constitutive relation were combined with the Johnson-Cook fracture criterion. These models were implemented as user-defined material models in the non-linear finite element code LS-DYNA. Identification procedures have been proposed, and the different models were calibrated and validated for the target material using available experimental data obtained from tensile tests where the effects of strain rate, temperature and stress triaxiality were taken into account. Perforation tests carried out in a compressed gas gun on 12-mm-thick circular Weldox 460 E steel plates were then used as base in a validation study of plate perforation using LS-DYNA and the proposed constitutive relations. The numerical study indicated that the physical mechanisms during perforation can be qualitatively well predicted by all constitutive relations, but quantitatively more severe differences appear. The reasons for this are discussed in some detail. It was concluded that for practical applications, the Johnson-Cook constitutive relation and fracture criterion seems to be a good choice for this particular problem and excellent agreement with the experimental results of projectile impact on steel plates were obtained under the conditions investigated.     

Indirect measuring of crack growth by means of a key-curve-method in pre-cracked Charpy specimens made of nodular cast iron

The determination of dynamic crack resistance curves from single specimen fracture tests requires information about the crack advance during the experiment. Here, attention is focused on crack resistance curves for nodular cast iron based on experimental data from instrumented Charpy tests. In order to estimate the actual crack length a key curve method (KCM) is employed. On the other hand, the Charpy impact tests were realized numerically using finite element calculations in conjunction with a continuum damage model (CDM) to simulate ductile crack growth. The parameters of the CDM model were determined from the experimental data of single specimen fracture tests. Equivalence between the experimental and the numerical realization of a fracture test was ensured by validating the predictions of the numerical simulations by means of low blow fracture tests. Comparison between the crack advance predicted by the numerical simulations and the results obtained using the proposed KCM shows a sufficiently well agreement with the actual crack length. Furthermore, crack resistance curves obtained from single specimen tests using either standard estimation schemes in conjunction with the KCM or numerical simulations are compared with the predictions based on low blow fracture tests.     

Simulation and Experimental Work on a Thin-Walled Structure Under Crushing

This study investigates a thin-walled cylindrical structure subjected to impact loading. Both simulations and experiments were performed to predict the deformation mode and its deformation rate. In the simulation, a three-dimensional finite element model of a soft drink can was developed and post-processed using ANSYS and LS-DYNA commercial packages, respectively. The experimental work was carried out by dropping a flat weight from a certain height to crush the specimen, using a drink can to represent the thin-walled structure. A high-speed camera was employed to capture the entire process of the crush. The simulation and experiment showed strong agreement.     

Numerical simulation of underwater explosion bulge test

Ambient temperature underwater explosion bulge test is simulated using ANSYS/LS-DYNA. Elastic and inelastic numerical experiments are carried out. Inelastic prediction is validated with a physical experimental data. Terminal strain to fracture is established. A methodology is thus arrived at for carrying out the material qualification for explosive loading using numerical simulation.     

On quasi-static crushing of thin-walled steel structures in cold temperature: Experimental and numerical studies

The aim of the study reported herein was to investigate the effects of low temperatures on the crushing characteristics of steel plated structures. The motivation of this study is for the analysis of ship collisions in Arctic waters. A series of tensile coupon tests were performed to examine their material behaviour at low temperatures, and then quasi-static axial crushing tests were carried out on thin-walled square tubes. The test tubes were made of ASTM A500-type carbon steel, and both the tensile coupon tests of the material and the crushing tests of the tubes were performed in a liquid nitrogen cooled chamber. To reflect the conditions of the Arctic environment more realistically, the tensile coupon tests of the material were also carried out in a dry-ice cooled chamber. LS-DYNA nonlinear finite element method simulations applying a practical approach of modelling techniques were performed to investigate the structural crashworthiness of the thin-walled steel tubes numerically. The tests in the liquid nitrogen cooled chamber showed that the fracture strain of the material was not affected (reduced) by temperatures as low as −80 °C, although fracture strain was significantly reduced below −100 °C. The fracture strain results obtained in the dry-ice cooled chamber, however, show this strain to be affected (reduced) by low temperatures even between 0 °C and −80 °C, which is equivalent to the Arctic environment. It was also observed that fracture occurs in thin-walled tubes under crushing loads at low temperatures. The LS-DYNA computations also detected the fracture behaviour of test tubes in cold temperatures in a relevant way.     

Modeling of material failure in foam-based components

The modeling of material failure in foam-filled beams was explored through numerical analyses with LS-DYNA. The study was based on previous physical tests on bending of square aluminum extrusions filled with aluminum foam. Recently implemented material models including fracture criteria for both extrusion and foam were used in the analyses. The objectives were to verify the numerical model, and to investigate the influence of different fracture criteria on the response.     

Quasi-brittle fracture during structural impact of AA7075-T651 aluminium plates

The stress–strain behaviour of the aluminium alloy 7075 in T651 temper is characterized by tension and compression tests. The material was delivered as rolled plates of thickness 20 mm. Quasi-static tension tests are carried out in three in-plane directions to characterize the plastic anisotropy of the material, while the quasi-static compression tests are done in the through-thickness direction. Dynamic tensile tests are performed in a split Hopkinson tension bar to evaluate the strain-rate sensitivity of the material. Notched tensile tests are conducted to study the influence of stress triaxiality on the ductility of the material. Based on the material tests, a thermoelastic–thermoviscoplastic constitutive model and a ductile fracture criterion are determined for AA7075-T651. Plate impact tests using 20 mm diameter, 197 g mass hardened steel projectiles with blunt and ogival nose shapes are carried out in a compressed gas-gun to reveal the alloy's resistance to ballistic impact, and both the ballistic limit velocities and the initial versus residual velocity curves are obtained. It is found that the alloy is rather brittle during impact, and severe fragmentation and delamination of the target in the impact zone are detected. All impact tests are analysed using the explicit solver of the non-linear finite element code LS-DYNA. Simulations are run with both axisymmetric and solid elements. The failure modes are seen to be reasonably well captured in the simulations, while some deviations occur between the numerical and experimental ballistic limit velocities. The latter is ascribed to the observed fragmentation and delamination of the target which are difficult to model accurately in the finite element simulations.     

An experimental and numerical study of the effects of length scale and strain state on the necking and fracture behaviours in sheet metals

Within sheet metal forming, crashworthiness analysis in the automotive industry and ship research on collision and grounding, modelling of the material failure/fracture, including the behaviour at large plastic deformations, is critical for accurate failure predictions. In order to validate existing failure models used in finite element (FE) simulations in terms of dependence on length scale and strain state, tests recorded with the optical strain measuring system ARAMIS have been conducted. With this system, the stress–strain behaviour of uniaxial tensile tests was examined locally, and from this information true stress–strain relations were calculated on different length scales across the necking region. Forming limit tests were conducted to study the multiaxial failure behaviour of the material in terms of necking and fracture. The failure criteria that were verified against the tests were chosen among those available in the FE software Abaqus and the Bressan–Williams–Hill (BWH) criterion proposed by Alsos et al, 2008. The experimental and numerical results from the tensile tests confirmed that Barba's relation is valid for handling stress–strain dependence on the length scale used for strain evaluation after necking. Also, the evolution of damage in the FE simulations was related to the processes ultimately leading to initiation and propagation of a macroscopic crack in the final phase of the tensile tests. Furthermore, numerical simulations using the BWH criterion for prediction of instability at the necking point showed good agreement with the forming limit test results. The effect of pre-straining in the forming limit tests and the FE simulations of them is discussed.     

Injury tolerance of tibia for the car–pedestrian impact

Lower limbs are normally the first contacted body region during car–pedestrian accidents, and easily suffer serious injuries. The previous tibia bending tolerances for pedestrian safety were mainly developed from three-point bending tests on tibia mid-shaft. The tibia tolerances of other locations are still not investigated enough. In addition, tibia loading condition under the car–pedestrian impact should be explored to compare with the three-point bending. This work aims to investigate the injury tolerance of tibia fracture with combined experimental data and numerical simulation. Eleven new reported quasi-static bending tests of tibia mid-shaft, and additional eleven dynamic mid-shaft bending test results in the previous literature were used to define injury risk functions. Furthermore, to investigate the influence of tibia locations on bending tolerance, finite element simulations with lower limb model were implemented according to three-point bending and pedestrian impact conditions. The regressive curve of tibia bending tolerance was obtained from the simulations on the different impact locations, and indicated that tibia fracture tolerance could vary largely due to the impact locations for the car–pedestrian crash.     

Strength and ductility of Weldox 460 E steel at high strain rates, elevated temperatures and various stress triaxialities

Strength and ductility data at high strain rates for Weldox 460 E steel was obtained from tensile tests with axisymmetric specimens. The tests were performed in a Split Hopkinson Tension Bar and the initial temperature was varied between 100 and 500 °C. The combined effect of high strain rate, elevated temperature and stress triaxiality on the behaviour was studied by testing both smooth and pre-notched specimens. It was found that the influence of temperature on the stress-strain behaviour differs at high strain rates compared with quasi-static loading conditions. The true fracture strain depends considerably on the stress triaxiality, which is governed by the notch geometry, while the influence of strain rate and temperature is less clear. Numerical simulations with the explicit finite element code LS-DYNA were performed using a model of elasto-viscoplasticity and ductile damage, which is based on the constitutive relation and fracture criterion of Johnson and Cook. The numerical simulations compare reasonably well with the experiments with respect to strength and ductility for both smooth and notched specimens at elevated temperatures.     

某特种车空投着陆过程数值仿真分析与改进

在基于LS-DYNA的环境中对某特种车整车的空投着陆进行了数值仿真研究。根据该特种车空投着陆的实际要求和整车结构尺寸,采用有限元软件HyperMesh建立空投着陆特种车整车的有限元模型,调用LS-DYNA求解器进行求解,最后利用LS-PREPOSTD做后处理。通过数值仿真结果和试验数据的对比,验证了该整车有限元模型的有效性。根据数值仿真结果,分析了该特种车车架的受力情况,提出了一些相应的改进措施,从而为车架的实际优化提供了依据。     

FRP-混凝土三点受弯梁损伤粘结模型有限元分析

该文采用双线形损伤粘结模型研究带切口FRP-混凝土三点受弯梁(3PBB)I型加载下的界面断裂性能。通过有限元参数分析,详细讨论了界面粘结强度、界面粘结能、混凝土抗拉强度、混凝土断裂能对3PBB受力性能的影响。数值模拟表明,FRP-混凝土界面有两种破坏形式,包括FRP-混凝土界面的损伤脱粘和界面混凝土的损伤脱粘破坏,与实验所观察到的现象一致。两种破坏形式尽管在宏观上均表现为界面脱粘,但破坏机制却不同。FRP-混凝土界面的损伤粘结模型与混凝土的拉伸塑性损伤模型相结合,不但再现了3PBB的宏观力学性能,数值分析得到的荷载-位移曲线接近实验结果,而且还能详细展示FRP-混凝土界面的损伤、断裂破坏过程以及损伤在FRP-混凝土界面和界面混凝土之间的转移,能够预测构件的承载力,有助于界面优化设计,这是单纯以能量判据预测裂纹发展的经典断裂力学方法所无法做到的。     

Effect of microscopic damage events on static and ballistic impact strength of triaxial braid composites

The reliability of impact simulations for aircraft components made with triaxial braided carbon fiber composites is currently limited by inadequate material property data and lack of validated material models for analysis. Methods to characterize the material properties used in the analytical models from a systematically obtained set of test data are also lacking. A macroscopic finite element based analytical model to analyze the impact response of these materials has been developed. The stiffness and strength properties utilized in the material model are obtained from a set of quasi-static in-plane tension, compression and shear coupon level tests. Full-field optical strain measurement techniques are applied in the testing, and the results are used to help in characterizing the model. The unit cell of the braided composite is modeled as a series of shell elements, where each element is modeled as a laminated composite. The braided architecture can thus be approximated within the analytical model. The transient dynamic finite element code LS-DYNA is utilized to conduct the finite element simulations, and an internal LS-DYNA constitutive model is utilized in the analysis. Methods to obtain the stiffness and strength properties required by the constitutive model from the available test data are developed. Simulations of quasi-static coupon tests and impact tests of a represented braided composite are conducted. Overall, the developed method shows promise, but improvements that are needed in test and analysis methods for better predictive capability are examined.     

Adhesion investigation of low-k films system using 4-point bending test

This research presents a simulation-based methodology to accurately predict interfacial adhesion behaviors of heterostructures. Validation of the proposed approach is achieved through comparison of 4-point bending test results on interfaces of multiple stacked low-k films with those of theoretical solutions from the finite element analysis. Impact induced by the compliance of 4-point bending test system can be neglected using the averaged energy release rate of various crack lengths in simulations. On the basis of precise predictions drawn from the considered analyses, uncertainty of experimental tests for the nano-scale fractured strength could be promptly observed and estimated.     

The effect of target strength on the perforation of steel plates using three different projectile nose shapes

The effect of target strength on the perforation of steel plates is studied. Three structural steels are considered: Weldox 460 E, Weldox 700 E and Weldox 900 E. The effects of strain hardening, strain rate hardening, temperature softening and stress triaxiality on material strength and ductility are determined for these steel alloys by conducting three types of tensile tests: quasi-static tests with smooth and notched specimens, quasi-static tests at elevated temperatures and dynamic tests over a wide range of strain rates. The test data are used to determine material constants for the three different steels in a slightly modified version of the Johnson–Cook constitutive equation and fracture criterion.Using these three steel alloys, perforation tests are carried out on 12 mm-thick plates with blunt-, conical- and ogival-nosed projectiles. A compressed gas gun was used to launch projectiles within the velocity range from 150 to 350 m/s. The initial and residual velocities of the projectile were measured, while the perforation process was captured using a digital high-speed camera system. Based on the test data the ballistic limit velocity was obtained for the three steels for the different nose shapes. The experimental results indicate that for perforation with blunt projectiles the ballistic limit velocity decreases for increasing strength, while the opposite trend is found in tests with conical and ogival projectiles. The tests on Weldox 700 E and Weldox 900 E targets with conical-nosed projectiles resulted in shattering of the projectile nose tip during penetration.Finally, numerical simulations of some of the experimental tests are carried out using the non-linear finite element code LS-DYNA. It is found that the numerical code is able to describe the physical mechanisms in the perforation events with good accuracy. However, the experimental trend of a decrease in ballistic limit with an increase in target strength for blunt projectiles is not obtained with the numerical models used in this study.