Macro-architectured cellular materials: Properties,characteristic modes,and prediction methods

Macro-architectured cellular (MAC) material is defined as a class of engineered materials having configurable cells of relatively large (i.e., visible) size that can be architecturally designed to achieve various desired material properties. Two types of novel MAC materials, negative Poisson’s ratio material and biomimetic tendon reinforced material, were introduced in this study. To estimate the effective material properties for structural analyses and to optimally design such materials, a set of suitable homogenization methods was developed that provided an effective means for the multiscale modeling of MAC materials. First, a strain-based homogenization method was developed using an approach that separated the strain field into a homogenized strain field and a strain variation field in the local cellular domain superposed on the homogenized strain field. The principle of virtual displacements for the relationship between the strain variation field and the homogenized strain field was then used to condense the strain variation field onto the homogenized strain field. The new method was then extended to a stress-based homogenization process based on the principle of virtual forces and further applied to address the discrete systems represented by the beam or frame structures of the aforementioned MAC materials. The characteristic modes and the stress recovery process used to predict the stress distribution inside the cellular domain and thus determine the material strengths and failures at the local level are also discussed.     

Elasto-plastic damage model considering cohesive matrix interface layers for composite laminates

A three-dimensional (3D) Finite element (FE)-based progressive damage model, which considers the interface matrix layer between two neighboring laminae as a layer of cohesive elements, is proposed to analyze laminated composite plates. An elasto-plastic damage model is integrated with the FE-based program ABAQUS that uses user-defined material subroutine. The present damage model includes fiber failure, matrix failure, and delamination effects. A cohesive zone model, which is available in ABAQUS and uses cohesive elements, is combined with the proposed model to address the delamination damage in the interface layers. 3D solid brick elements are used to model composite layers, and cohesive zone elements are used in between two composite layers to model the adhesive layers. The proposed model has been applied for the progressive damage simulation of AS4/PEEK composite laminates under in-plane and uniaxial tensile loading.     

均匀化理论在多孔板结构优化中的应用研究

多尺度均匀化理论自从上世纪 70年代产生以来 ,就被认为是确定复合材料当量性能的一种不可替代的方法。本文将多尺度均匀化方法应用于基于有限元分析的多孔板结构优化设计中 ,简述了求解当量板有效弹性常数的均匀化理论 ,在此基础上 ,建立了基于有限元分析的多孔板结构优化流程 ,编写了FORTRAN程序 ,并将其与AN SYS软件相连接 ,完成了一个多孔板结构的优化设计 ,所得结果表明 ,它能够满足工程应用的需要 ,并为多孔板结构设计提供了一种新思路     

Effect of particulate/matrix debonding on the formation of adiabatic shear bands

We use the cohesive zone failure model to simulate debonding and failure in high strain-rate plane strain deformations of a heat conducting particulate composite comprised of initially circular metallic particulates immersed in a metallic matrix, with the goal of delineating the effect of these failures on the initiation and propagation of adiabatic shear bands (ASBs). Failure is assumed to ensue at an interface between two elements when a predefined combination of the normal and the tangential tractions on that interface reaches a critical value. We postulate that the critical value of the traction in the cohesive zone failure model decreases affinely with an increase in the temperature. Both particulate and matrix materials are assumed to be isotropic, heat conducting, and to obey the von Mises yield criterion with the flow stress depending upon the effective strain, the effective strain rate, and the temperature according to the Johnson-Cook relation. The coupled transient thermomechanical problem is analyzed by the finite element method by using 3-node triangular elements and the finite calculus technique to prevent volumetric locking. It is found that the critical strength of the bond between the particulate and the matrix significantly influences the loss of strength of the entire specimen. The time of initiation of an ASB is influenced by the time when debonding ensues which depends upon the values of the critical traction and the mode-mixity parameter in the cohesive zone failure criterion.     

Mode I failure modeling of friction stir welding joints

This paper analyzes mechanical response by finite element method up to the decohesion failure in fracture mode I for joints of friction stir welding (FSW) of an aluminum alloy. It first describes experimental investigations on specimens with FSW embedded, subjected to uniform traction and local punch tests used to characterize local elastic and plastic material parameters. The heterogeneity of the mechanical properties induced by the FSW process is taken into account for the elastic-plastic finite element simulation. The growing damage and the opening failure of the welding zone are described by the adoption of a cohesive interface model with specific mechanical properties.     

Homogenized elastic-viscoplastic behavior of plate-fin structures at high temperatures: Numerical analysis and macroscopic constitutive modeling

In this study, homogenized elastic-viscoplastic behavior of an ultra-fine plate-fin structure fabricated for compact heat exchangers is investigated. First, the homogenized behavior is numerically analyzed using a fully implicit mathematical homogenization scheme of periodic elastic-inelastic solids. A power-law creep relation is assumed to represent the viscoplasticity of base metals at high temperatures. The plate-fin structure is thus shown to exhibit significant anisotropy as well as noticeable compressibility in both the elastic and viscoplastic ranges of the homogenized behavior. Second, a non-linear rate-dependent macroscopic constitutive model is developed using the quadratic yield function proposed for anisotropic compressible plasticity. The resulting constitutive model is shown to be successful for simulating the anisotropy, compressibility, and rate dependency in the homogenized behavior in multi-axial stress states.     

Material removal mechanism of silicon nitride during rubbing in water

The material produced at the friction interface and the material removal mechanism were investigated for the rubbing of silicon nitride in water. The material removal rate estimated by the contact time of the specimen was constant at all rubbing speeds, which suggested that the material removal mechanism was attributable to the chemical reaction at the rubbing interface. The analytical results from the ion microprobe analysis spectra indicated that many ions of silicon with hydrogen and oxygen remained on the polished surface. Also, the rubbing remnants in the water were shown to be an amorphous material and were converted into α-cristobalite (SiO₂) by a heat treatment in air at 1170 K for 1 h. These results suggested that the oxidized silicon nitride was changed by friction to an amorphous hydrate SiO₂·xH₂O during rubbing in water and, after that, the amorphous hydrate was removed from the rubbing interface.     

The homogenization process of the Reynolds equation describing compressible liquid flow

This paper summarizes the homogenization process of rough, hydrodynamic lubrication problems governed by the Reynolds equation used to describe compressible liquid flow. Here, the homogenized equation describes the limiting result when the wavelength of a modeled surface roughness goes to zero. The lubricant film thickness is modeled by one part describing the geometry/shape of the bearing and a periodic part describing the surface topography/roughness. By varying the periodic part as well as its wavelength, we can try to systematically investigate the applicability of homogenization on this type of problem. The load carrying capacity is the target parameter; deterministic solutions are compared to homogenized by this measure. We show that the load carrying capacity rapidly converges to the homogenized results as the wavelength decreases, proving that the homogenized solution gives a very accurate representation of the problem when real surface topographies are considered.     

铸铁黏聚裂纹的张开位移与应力分布

对于含缺陷材料结构的强度,以裂纹为主要特征的断裂力学是其力学行为分析的有效途径,裂纹扩展过程区能被简化成具有黏聚力的裂纹段。为探讨带切口的铸铁裂纹发展规律及黏聚裂纹张开位移与黏聚应力的本构关系,对8种不同切口尺寸的铸铁梁进行三点弯曲加载实验,通过应变计电测跟踪测试,得到预制裂纹端部的张开位移随载荷变化曲线。由确定黏聚裂纹张开位移与黏聚应力分布的解析方法,计算得到该材料黏聚裂纹张开位移及与应力的本构关系。计算预制裂纹尖端张开位移与应变计测试结果基本符合。     

基于有限元的鼓泡试验模拟

采用ABAQUS内置的内聚力模型来表征电沉积镍涂层钢板的界面性能，运用张力－位移界面本构关系的界面力学模型，模拟了鼓泡试验的界面开裂过程，描述了界面从起始剥离到完全开裂过程的力学性能，得到了电沉积镍涂层钢板界面开裂的强度曲线，该方法以及所得的结果对板料成形的生产能起到一定的指导作用。     

搭接长度对平纹机织复合材料胶接结构连接性能影响的多尺度分析

针对平纹机织复合材料层合板,首先基于均匀化方法确定细观模型的性能参数,其次采用Hashin准则分析细观模型损伤过程,最后引入连续损伤力学模型和内聚力模型建立层合板胶接结构宏观模型。研究结果表明,平纹机织复合材料层合板的数值曲线与试验结果吻合较好,验证多尺度模型的有效性;搭接长度在5～15 mm时,随着搭接长度的增大,单搭和双搭胶接结构的极限失效载荷逐渐增大,并趋于稳定,而搭接剪切强度逐渐减小;单搭和双搭胶接结构的失效形式随着搭接长度的增大逐渐由胶层剪切失效过渡到层间分层失效;相同搭接长度下,与单搭胶接结构相比,双搭结构的极限失效载荷较大。基于均匀化方法、Hashin失效准则、内聚力模型和连续损伤力学模型,提出一种平纹机织复合材料多尺度模型,对结构性能设计和使用寿命具有重要意义。     

Structural topology optimization for the natural frequency of a designated mode

The homogenization method and the density function method are common approaches to evaluate the equivalent material properties for design cells composed of matter and void. In this research, using a new topology optimization method based on the homogenized material with a penalty factor and the chessboard prevention strategy, we obtain the optimal layout of a structure for the natural frequency of a designated mode. The volume fraction of nodes of each finite element is chosen as the design variable and a total material usage constraint is imposed. In this paper, the subspace method is used to evaluate the eigenvalue and its corresponding eigenvector of the structure for the designated mode and the recursive quadratic programming algorithm, PLBA algorithm, is used to solve the topology optimization problem.     

Computational simulations of delamination wear in a coating system

Delamination wear constitutes one relevant wear process in many materials. In particular, wear failure through delamination is relevant for material systems where a coating is present on a substrate material. A computational modeling approach is presented that aims to describe the processes of formation and growth of wear delaminations. The model is based on the cohesive zone model approach. An irreversible cohesive zone model is used in a parametric numerical study of delamination wear in a coating system. The model predicts trends in agreement with the trends emerging from Archard's law. The proposed modeling approach has the advantage that details of the delamination wear process can numerically be studied, and that a unified framework from delamination initiation and propagation is provided.     

器件韧性镀膜微划痕破坏机理研究

对硅基体上之韧性镀膜（铝膜）的粘结强度及破坏机理进行微划痕实验及理论研究,从实验中观察出该体系的破坏特征,进而测量出微划前水平驱动力、划痕深度随划前水平位移并伴随着界面脱胶发生的变化规律,针对微刈痕破坏特征,建立了双粘聚力模型,并对由微划痕引起的界面弹塑性脱胶进行了数值模拟,给出界面脱胶时能量释放率随其他材料参数变化的理论预测曲线,并将预测值与文中的铝／硅实验结果及与文献中关于铂／氧化镍的实验结果进行对比,达到基本符合。通过以对韧性薄膜／脆性基体的微划痕实验研究和理论分析,获得如下主要结论：（1）韧性膜的微划痕破坏特征为,当划刀尖端接近界面时,将突然发生薄膜测界面的脱胶现象,并在界面附近脆性基一侧形成界面裂纹并扩展;微划痕的水平驱动力表征了整个薄膜脱胶体系的能量释放率;薄膜或涂层材料的塑性变形对微划痕过程有较强的抑制作用。（2）界面的分离强度和材料的剪切强度对微划痕过程有重要的影响。（3）划痕刀片的几何特征角对刻痕水平驱动力影响不大。     

Effects of specimen tilt in ADF-STEM imaging of a-Si/c-Si interfaces

Annular dark field scanning transmission electron microscopy (ADF-STEM) imaging of a crystal depends strongly on specimen orientation, but for an amorphous sample it is insensitive to orientation changes. To fully investigate the effects of specimen tilt, an interface of amorphous Si (a-Si) and crystalline Si (c-Si) was rotated systematically off a zone axis in a STEM equipped with low-angle ADF (LAADF) and high-angle ADF (HAADF) detectors. The change of relative intensity across the interface shows very different trends in the LAADF and the HAADF images upon tilting. More importantly, it is found that the HAADF signal decreases much more rapidly when tilted off a zone axis than does the LAADF signal. The high-resolution lattice fringes also disappear much faster in the HAADF image than in the LAADF image. These trends reflect the fact that the channeling peaks that are responsible for scattering into the HAADF detector decrease more quickly upon tilting than the lower angle scattering to the LAADF detector does.     

Contact conditions at the chip-tool interface in machining

Direct observation of the chip-tool interface was made using transparent sapphire tools in combination with a CCD-based high-speed imagining system. The observations made for various nonferrous workpiece materials suggest that the contact conditions at the chip-tool interface be classified into three types depending on the nature of the zone of stagnant material — negligible zone of stagnant material (Type 1), zone of stagnant material that is stable and confined to the vicinity of the cutting edge (Type 2), and zone of stagnant material that expands upward from the cutting edge as cutting progresses (Type 3). Velocity profiles obtained using the particle image velocimetry (PIV) show that retardation of the chip underside occurs in the intimate contact region for the Type 2 materials while it is negligible for the Type 1 materials. Nanoindentation hardness profiles measured with depth into the chip from the chip underside indicate that the expansion of the zone of stagnant material observed for the Type 3 materials could be related to the work-hardenability of the chip material in the secondary deformation zone.     

气凝胶初级粒子导热系数的分子动力学模拟

采用分子动力学方法模拟融化-淬火工艺制备非晶态SiO2材料和SiO2气凝胶初级粒子单元。基于非平衡分子动力学(Non-equilibrium molecular dynamics,NEMD)理论计算体态材料和初级粒子单元的导热系数,计算过程考虑了冷热源引起的尺度效应。结果表明,计算得到的体态材料导热系数与文献计算结果吻合良好。对于初级粒子单元,在粒径2～6 nm范围内,粒子直径使得粒子单元导热系数出现了尺度效应,但是影响相对较小。粒子间界面直径对粒子单元导热系数影响很大,当粒子直径为3 nm时,界面直径从0.89 nm增加到2.49 nm,粒子单元导热系数增大了171.61%,粒子界面处的温度阶跃,表明存在明显的界面热阻效应;且界面直径越小,界面热阻越大。     

Metallic friction under near-seizure conditions

In metal-working theory extreme frictional (perfectly rough) conditions are assumed to apply when the shear stress opposing motion at the tool-work interface is equal to the shear flow stress of the work material. This is normally likened to seizure (sticking) with zero velocity at the actual interface and with plastic flow occurring in the adjacent work material. If the flow stress is assumed constant as in ideal plasticity theory, then this condition can be readily defined. However, if the flow stress is allowed to vary with, for example, strain rate and temperature, it is no longer obvious at what value of flow stress the perfectly rough condition becomes applicable. With the assumption that the velocity changes from zero at the interface to the full rigid body velocity over a narrow plastic zone of intense shear, an analysis is presented in which it is proposed that the thickness of this zone (which must be finite in a strain-rate-sensitive material) and hence the associated strain rate, temperature and flow stress are determined by a minimum work criterion. Recent results in support of this are presented from machining experiments where the flow at the tool-chip interface approximates to perfectly rough conditions. It is suggested that for steady state conditions true seizure cannot occur and a possible mechanism is given for near-seizure conditions in which the velocity at the interface, although very low, is not zero.     

Finite element modeling of the scratch response of a coated time-dependent solid

Scratch tests is one of the most efficient tests to investigate the mechanical resistance of coated and uncoated surfaces. Nevertheless, the complexity of material and interface makes difficult the comprehension of this test. For that purpose, efficient computational modeling is required. In this paper, we present a remeshing procedure specially developed for the computational modeling of scratch tests of coated materials. This procedure allows to perform scratch tests with high ratio penetration depth over layer thickness. Then, it is used to investigate the influence of the scratching velocity on the scratch behavior of a polymer substrate coated with a hard elastic coating. The substrate is considered as an elastic–viscoplastic solids and the coating follows a linear elastic behavior. First macroscopic results such as material deformation, scratch hardness and apparent friction coefficient are presented. Then the stress distribution in the film and at the coating/substrate interface are analyzed regarding the cohesive or interfacial failure of the system. A simple interfacial failure criterion is also proposed.     

The crystallographic change in sub-surface layer of the silicon single crystal polished by chemical mechanical polishing

The effect of the contact nominal pressure on the surface roughness and sub-surface deformation in chemical mechanical polishing (CMP) process has been investigated. The experimental results show that a better surface quality can be obtained at the lower pressure, and the thickness of sub-surface deformation layer increases with the increase of the pressure. In CMP process, polishing not only introduces amorphous transformation but also brings a silicon oxide layer with a thickness of 2–3 nm on the top surface. The atomic structure of the material inside the damage layer changes with the normal pressure. Under a higher pressure (125 kPa), there are a few crystal grain packets surrounded by the amorphous region in which the lattice is distorted, and a narrow heavy amorphous deformation band appears on the deformation region side of the interface. Under a lower pressure, however, an amorphous layer can only be observed.