Comparison and analysis of experimental and virtual laboratory scale punch through tests

Laboratory scale punch through tests on floating rubble consisting of plastic blocks were conducted and simulated with a 3D discrete numerical model. The purpose was to analyse the experimental method and to validate the model. The motivation of using plastic blocks instead of ice was to simplify the interpretation of results as the plastic blocks do not freeze together. The indentor force and the lateral force induced by the rubble on one of the basin walls were recorded as a function of indentor penetration. Further, the experiments were recorded with a video camera and a motion tracking software was used to analyse the rubble deformation. The force records and deformation patterns from the experiments and simulations were in agreement. The evolution of the deformation patterns could be closely linked to the indentor force records, which demonstrates the need for the numerical model to correctly represent the rubble deformation. The experiments and the simulations showed, that the lateral force within the pile increased considerably during a punch through experiment. This makes the interpretation of punch through experiment results for material modelling challenging: the friction angle of the rubble can become overestimated making the punch through test unsuitable for achieving accurate values for friction angle. Consequently, no value for the rubble friction angle was derived here.     

3D discrete numerical modelling of ridge keel punch through tests

Ridge keel punch through tests were simulated in 3D. In simulations unconsolidated ridge keel was modelled as a rubble pile of loose ice blocks. Combined finite–discrete element method (FEM–DEM) with rigid discrete elements representing ice blocks was used. Simulations were run in full scale. In total 47 simulations were run with various friction coefficients and keel depths. The failure process of simulated rubble piles was analysed and the shear strength of the rubble pile was derived from results. The effect of rubble porosity, keel depth and friction on shear strength of the pile was also analysed. The simulation results were compared to laboratory and full-scale punch through tests of unconsolidated ice rubble. Shear strength values achieved from simulations were in range for experimental results. Failure process was observed to be similar to laboratory experiments.     

Mechanical properties of model ice ridge keels

Rubble ice presents pressure dependent yield strength and its behaviour can be described by mathematical models based on several mechanical parameters. They are investigated for HSVA model rubble ice through the analysis of three different tests: the oedometer test, the pile test and the punch test. This last test is analysed with the non-linear Eulerian finite element method. The tests were performed on 4 ice ridges with two different submersion times. A 0.5 to 1.2 kPa model scale Mohr-Coulomb cohesion (0.6 to 1.5 kPa Drucker-Prager cohesion), depending on the ridge history, was used in the simulations of the model scale punch tests. The friction angle is estimated between 30 and 45° (40 and 50° Drucker-Prager friction angle). The upper value was used in the punch test simulations. A 0.9 MPa Young modulus was derived and the hydrostatic compressive yield curve was determined. The numerical model is able to estimate the rubble action during the entire penetration of the punch test in the keel and it is shown that a cohesive softening occurs in the rubble. In order to reproduce the experimental load time series for the short submersion time ridges it was necessary to use a vertical distribution of the cohesion representing the vertical distribution of the freeze-bond strength. A sensitivity analysis of the punch test shows that the keel depth and the ice density are the main parameters governing the keel frictional resistance. A precise determination of these parameters is therefore crucial for a correct determination of the rubble mechanical properties from the numerical simulation of experimental punch tests. The punch test is not appropriate for the determination of the friction angle due to the low confinement pressure at the failure plane. The numerical analysis of the punch test allows the estimation of different assumptions used in analytical models for the rubble failure: the cohesion averaging is an under-conservative approximation, and the non-simultaneity of the cohesive and shear resistance maximum values can be considered in the peak load estimation by the computation of their quadratic mean. The comparison with full scale values shows a reasonably good scaling of the cohesion for the model ice ridges with a long submersion time.     

Simple-shear box experiments with floating ice rubble

A simple-shear box was used to study the shear strength characteristics of floating layers of vertically unconstrained ice rubble comprised of parallelpiped ice blocks. A comparative set of experiments was also performed using floating layers of parallelpiped plastic blocks in order to determine the origin of cohesion in ice rubble. Experiments were also performed using mushy ice. However, the shear-box proved not to be useful for determining the shear testing of mushy ice.The shear strength of a layer of ice rubble was found to depend on normal stress, which in turn was found to depend on rubble thickness, layer porosity, and shear rate. The dependence on shear rate of normal stress and, as a consequence, of shear strength of a layer of floating ice rubble is attributed to the development of freeze-bonds between the ice blocks comprising the rubble layer. It is argued that, at slower shear rates, more and stronger freeze-bonds develop than at higher shear rates, thus enabling the layer to withstand larger normal stresses and, consequently, shear strengths that increase with decreasing shear rates. If the influence of freeze-bonding on normal stress is taken into account, and if a Mohr-Coulomb failure criterion is used to characterize shear strength, it is found that a floating layer of ice rubble undergoing continuous-shear deforms as a cohesionless material; or at least as a material with unique cohesive properties.     

Numerical modelling of ice ridge keel action on subsea structures

The present paper describes a numerical simulation of the keel-structure interaction where the keel geometry, ice thickness and interaction speed present a scaling ratio of 1:20. The rubble is represented by a Drucker-Prager material with cohesive softening and no dilatation. The partial differential equations are solved with the non-linear Eulerian finite element method of Abaqus Explicit V6.8.2. The results are compared to physical experiments conducted in the ice basin of the Hamburg ship model basin (HSVA). Two identical cubic subsea structures were impacted into the unconsolidated keel portion of two ice ridges with different thermal properties. The results indicate that only slight dilatation occurs, and the models are able to estimate the rubble action and deformed shape. A progressive failure of the rubble occurs. The rubble action is influenced more by the friction angle than it is in punch tests, due to higher confinement at the failure surface.     

Explicit FEM analysis of the deep drawing of paperboard

An explicit finite element model of the deep-drawing of paperboard has been developed utilizing a custom yet simple material model which describes the anisotropy and plasticity of paperboard. The model was verified with a variety of tests and was then utilized to compare the punch force that was measured during the deep-drawing experiments to the punch force that was calculated during the deep-drawing simulations. All material parameters were calibrated based on individual experiments; thus, no parameter fitting was utilized to match the experimental deep-drawing results. The model was found to predict the experimental results with reasonable accuracy up to the point when wrinkling began to dominate the material response. Since most failures during paperboard deep-drawing occur before wrinkling begins to play a major role, this model can probably be utilized to study and predict the failure of deep-drawn paperboard cups. The overall trends and the effects of major process parameters are predicted by the model. The process parameters that were varied and compared for both experiments and simulations were: blankholder force, die temperature, and thickness. The model was utilized to discover that friction of the blankholder and die have significant effects on the punch force and thus the stress, implying that low-friction dies and blankholders can considerably reduce the failure probability and thus also improve the quality of deep-drawn paperboard cups.     

Prediction of the first failure energy of circular carbon fibre reinforced plastic plates loaded at the centre

This work was devoted to the prediction of the elastic energy stored at first failure in a circular composite plate statically loaded at the centre. To describe the load–deflection curve, a previous model was further developed, to explicitly account for the tup diameter. The first failure load was calculated through a simple formula, available in the literature, which was suitably varied. An original expression was derived for the energy at first failure.The experimental tests were carried out on carbon fibre reinforced plastic laminates of various thicknesses, which were simply supported at the periphery and loaded using different support and indentor diameters. The results obtained show that the elastic model, which takes into account the non-linearity deriving from large displacements and local indentation, is very accurate in shaping the load–deflection curve up to the first failure point. In general, also the predicted load and energy at first failure are in good agreement with the corresponding measured values. Both theory and experiments demonstrate that the critical load is independent of the support diameter, whereas it increases with increasing the plate thickness and the indentor diameter. When the support diameter and thickness increase, the energy at first failure increases as well.A particular condition, resulting in the failure of the force model, is achieved when the curvature of the plate at first failure is considerable. In this case, critical forces notably higher than expected from theory are measured. A possible explanation for this behaviour is given.     

Model tests on ice-rubble size and ship resistance in ice rubble

Described here are the results of model tests on resistance to ship-hull motion through a thick layer of ice rubble; layer thickness was 45% of hull draft. The tests were aimed to elucidate the influences of ice-rubble size on ice-rubble resistance. It was found that as ice-rubble size increased so did the resistance encountered by the test hull. However, it was also found that a layer of mush ice produced a greater resistance than did layers comprised of ice blocks. A layer comprised of both mush ice and ice blocks produced a resistance intermediate to layers comprised of either mush ice or ice blocks.Ship resistance generally increased with increasing ship speed. However, the influences of ship speed and ice-rubble size on the contributing resistance processes were found to be somewhat more complex. For example, the frictional resistance experienced by the parallel midbody of the test hull initially decreased with increasing ship speed, when the ice rubble was comprised of ice blocks which were small compared to layer thickness and hull size. The frictional resistance subsequently increased then decreased again with increasing ship speed. When the layer was comprised of relatively large ice blocks, frictional resistance increased to a maximum value then decreased with increasing ship speed. Generally, larger frictional resistance occurred for the layers comprised of larger ice rubble. In accordance with the relative sizes of ice rubble and ship hull, and with hull speed, the variations in frictional resistance can be explained in terms of a layer behaving as either a granular medium or as a viscous fluid.An additional aim of the study was to verify the existence of a thrust due to the ascension of submerged ice at a hull's stern. The existence of a stern thrust had been postulated by Kitazawa and Ettema (1985). The present study indicates that a relatively weak stern thrust may occur, but its magnitude is negligibly small compared to other resistance forces.     

Experiments on level ice loading on an icebreaking tanker with different ice drift angles

A series of tests was performed with a laboratory-scale model ship to simulate the effects of ice load parameters on an icebreaking tanker. A model of the icebreaking tanker Uikku was mounted on a rigid carriage and towed through an unbroken ice sheet in the ice tank of the Marine Technology Group at Aalto University. Two ice sheets and 11 different experimental configurations were used. The carriage speed, heading angle of the model ship, and ice thickness were varied, and the forces, accelerations, ice cusp sizes, carriage positions, and ice pile dimensions under the intact ice sheets were measured.This paper includes results for the measurements of ice rubble loads against the model hull in the horizontal plane. Phenomena such as ice failure modes and ice rubble accumulation on the upstream side of the hull beneath the ice sheet were observed in some tests. The icebreaking lengths and dimensions of ice rubble were analyzed for some tests. The effects of towing speed, heading angle under the intact ice sheet in front of the hull, and the accompanying ice loads on the formation and build-up of ice rubble were analyzed. In addition, the evolution of ice rubble geometry, in cross sections and the horizontal plane, was investigated. There was good agreement over several orders of magnitude between the measured and calculated values of the lateral ice forces. These results are relevant to the modeling of ice loading on hulls and the design of moored or dynamic positioned structures for operation in ice-covered waters. Some parameters obtained from these tests can be used as input for future numerical simulations.     

Small punch testing and its numerical simulations under constant deflection force conditions

A comparison of results of small punch tests on miniaturized discs under a constant force with their simulation by means of FEM is presented. A heat-resistant steel of type CSN 41 5313 (EN 10CrMo9-10) was selected for our investigations. The small punch tests as well as the necessary conventional creep tests on massive specimens were performed at 873 K. For simulations, the Norton power-law and the exponential relationships were applied in the FEM model of the SPT arrangement. Parameters of both relationships were derived from stress dependences of minimum creep rate obtained from the conventional creep tests. While at higher loads the Norton power-law yields results more comparable with those obtained from experiments, at lower loads the exponential relationship gives better results. The investigation also confirms the simple relation between stress in conventional tests and force in small punch tests resulting in identical time to fracture of both types of tests. __________ Translated from Problemy Prochnosti, No. 1, pp. 32–35, January–February, 2008.     

Effects of yield surface shape on sheet metal forming simulations

Three phenomenological yield criteria are adopted to describe the plastic behaviour of sheet metals with normal plastic anisotropy. The sheet metals are assumed to be elastic-plastic, rate-sensitive and incompressible. A rate-sensitive thin shell finite element formulation based on the virtual work principle is derived for the three yield criteria. The effects of the yield surface shapes based on the three yield criteria with the same value of the plastic anisotropy parameter R on the strain distribution and localization are investigated under a hemispherical punch stretching operation and a plane strain rawing operation. The results of the simulations show that the yield surface shape, in addition to the plastic anisotropy parameter R, controls the punch force, strain distribution and strain localization for the punch stretching operation. However, the yield surface shape does not affect the punch force and the strain distribution significantly for the plane strain drawing operation. © 1998 John Wiley & Sons, Ltd.     

A new approach of using Lorentz force to study single-asperity friction inside TEM

Taking advantage of the magnetic field inside transmission electron microscope(TEM),a unique Lorentz-force-actuated method for quantitative friction tests was developed via a commercial electromechanical holder.With this approach,a submicron-sized silver asperity sliding on a tungsten flat punch was actu-ated by Lorentz force due to electrical current through the punch,with the normal force imposed by the built-in transducer of the holder.The friction force was determined by tracking the elastic deflec-tion of the fabricated cantilever from in situ video.Through correlating the friction behavior with the microstructural evolution near the silver-tungsten interface,we revealed that even when the relative motion commenced with the plastic deformation of the silver asperity,the interface can still sustain the further increasing static friction force.Exactly following the arrival of the maximum static friction force,the sliding occurred at the interface,indicating the transition from static to dynamic friction.This work enriches our understanding of the underlying physics of the dynamic friction process for metallic friction behavior.     

Numerical and experimental analysis of wrinkling during the cup drawing of an AA5042 aluminium alloy

The recent trend to reduce the thickness of metallic sheets used in forming processes strongly increases the likelihood of the occurrence of wrinkling. Thus, in order to obtain defect-free components, the prediction of this kind of defect becomes extremely important in the tool design and selection of process parameters. In this study, the sheet metal forming process proposed as a benchmark in the Numisheet 2014 conference is selected to analyse the influence of the tool geometry on wrinkling behaviour, as well as the reliability of the developed numerical model. The side-wall wrinkling during the deep drawing process of a cylindrical cup in AA5042 aluminium alloy is investigated through finite element simulation and experimental measurements. The material plastic anisotropy is modelled with an advanced yield criterion beyond the isotropic (von Mises) material behaviour. The results show that the shape of the wrinkles predicted by the numerical model is strongly affected by the finite element mesh used in the blank discretization. The accurate modelling of the plastic anisotropy of the aluminium alloy yields numerical results that are in good agreement with the experiments, particularly the shape and location of the wrinkles. The predicted punch force evolution is strongly influenced by the friction coefficient used in the model. Moreover, the two punch geometries provide drawn cups with different wrinkle waves, mainly differing in amplitude.     

航空用GH625镍基高温合金带材的成形极限研究

目的 通过理论预测及胀形实验建立GH625高温合金的成形极限曲线,并结合仿真手段揭示其成形性能.方法 首先,通过基本力学性能测试获取不同方向下GH625材料的基本力学参数;然后,基于颈缩理论和M-K理论模型预测GH625材料的成形极限曲线;其次,通过胀形实验建立相应的成形极限图,并与理论结果进行对比;最后,结合有限元方法进一步研究GH625材料的成形特性.结果 准确获得了GH625高温合金的塑性应变比r值、应变硬化指数n值等参数;通过理论模型及胀形实验分别获得了相应的成形极限曲线,基于颈缩理论的集中性失稳预测结果与实验结果吻合较好;建立了可靠的有限元模型,进一步分析了摩擦因数及球头直径对GH625材料成形性能的影响规律.结论 建立了准确的GH625材料成形极限曲线的理论预测模型,并通过半球胀形实验验证了理论结果的可靠性,数值仿真结果发现,较小的摩擦因数或者冲头直径有利于改善GH625材料在胀形实验中的失效位置.     

Autoclaved aerated concrete (AAC) rubble for new recycling building products: In dry premixed mortars for masonry,in masonry blocks and in lightweight blocks

In cooperation of Bremen Institute for Materials Testing (MPA Bremen), a Department of Leibniz Institute for Materials Engineering IWT, Bremen University of Applied Sciences and the Research Association RWB Bremen building products for masonry structures were developed on the basis of AAC rubble from C&D wastes. Granulates from processed AAC rubble were introduced as aggregates in dry premixed masonry mortars, in masonry blocks and lightweight building blocks and elements to replace completely natural aggregates. These recycling products exhibit beneficial technical properties, at the same time large volumes of AAC wastes may be re‐used. On the basis of the achieved R&D‐results from laboratory experiments, trial batches of dry premixed mortar and masonry blocks were produced in the building materials industry on their available industrial equipment, minor adjustments in the mix composition were necessary. After a sufficient amount of dry premixed mortar and masonry blocks were produced, the recycling products were used to erect indoor masonry walls in a building project in Bremen.     

Prolonged plastic deformation related to the microindentation of MgO single crystals

The plastic deformation regions near the indentations on the (0 0 1) plane of MgO single crystals were investigated for an indentor under load and after unloading. It was established that the completion of slip-line structures arising during indentor penetration occurred during indentor removal. The presence of prolonged plastic deformation has been explained by considering the impulse character of the microindentation process of MgO at room temperature.     

Experimental investigation into scaling laws for conical shells struck by projectiles

An experimental investigation is reported into the scaling laws for fully clamped thin-walled mild steel conical shells struck axially by plane-head cylindrical projectiles travelling at velocities between 29.5 and 54 m/s. The test shells and projectiles have scale factors of 1, 2 and 4. Some tests are conducted to determine the critical impact velocities to cause cracking or perforation. The other tests are conducted with impact energies which produce dynamic plastic buckling without any rupture or cracking. The critical velocities and the permanent axial deflections of the shells do not obey the elementary geometrically similar scaling laws. The larger deviations are related with the higher impact velocities and larger scale factors. The material strain rate sensitivity effects may be the main factor causing the deviations. The other factor is the localization of the deformation during dynamic plastic buckling.     

Finite element modeling of impact, damage evolution and penetration of thick-section composites

Impact, damage evolution and penetration of thick-section composites are investigated using explicit finite element (FE) analysis. A full 3D FE model of impact on thick-section composites is developed. The analysis includes initiation and progressive damage of the composite during impact and penetration over a wide range of impact velocities, i.e., from 50 m/s to 1000 m/s. Low velocity impact damage is modeled using a set of computational parameters determined through parametric simulation of quasi-static punch shear experiments. At intermediate and high impact velocities, complete penetration of the composite plate is predicted with higher residual velocities than experiments. This observation revealed that the penetration-erosion phenomenology is a function of post-damage material softening parameters, strain rate dependent parameters and erosion strain parameters. With the correct choice of these parameters, the finite element model accurately correlates with ballistic impact experiments. The validated FE model is then used to generate the time history of projectile velocity, displacement and penetration resistance force. Based on the experimental and computational results, the impact and penetration process is divided into two phases, i.e., short time Phase I - shock compression, and long time Phase II - penetration. Detailed damage and penetration mechanisms during these phases are presented.     

High energy xenon ion beam assisted deposition of TiN film and its industrial application

TiN films have been synthesized by ion beam assisted deposition employing xenon ions with an energy of 40 keV. The formed TiN films were investigated systematically in respect of surface morphology, composition, structure and mechanical properties. Then, they were applied to surface protection of scoring dies. Atomic force microscopy and interferometric observation showed that the TiN film is relatively smooth. Rutherford backscattering spectroscopy analysis indicated that few xenon atoms are retained in the film. It was found by transmission electron microscopy and X-ray diffraction experiments that the formed TiN is a nanocrystal (< 10 nm) film and exhibits slightly (200) preferred orientation. An ultra low load microhardness indentor system was used to examine the plastic property of the film and a hardness of 2300 kgf mm^–2 was calculated from the measured data. Scratch tests showed that the adhesion of TiN film deposited by ion beam assisted deposition at ambient temperature is superior to that of high temperature physical vapour deposited (PVD) TiN film. Both a pin-on-dick tribotest and SRV wear test revealed that the wear resistance of the specimen can be greatly improved by TiN coating. A five times increase of service life of different scoring dies could be obtained by protection of TiN coating.     

The contact behavior between a foam core sandwich plate and a rigid indentor

The purpose of this paper is to determine the indentation produced by a rigid indentor falling on a sandwich plate with a height–density closed cellular foam core. Two different indentor shapes are considered: a rigid sphere and a cylindrical rigid punch. By assuming that the time of complete indentation of the indentors is much larger than the time required by the elastic waves to propagate from the point of first contact to the boundary of the plate, a static analysis is performed. A distribution of surface pressures reproducing the contact law of the rigid indentor on an elastic half-space is introduced and the sandwich plate theory proposed by Dundrová, Kovarı́k and Slapák (1970) is adopted; the explicit solutions with pre-assigned surface pressures are obtained and the contact force–indentation relations, before the sandwich plate is damaged, are found. The contact laws are obtained for both a simply supported and a clamped circular sandwich plate and the relevant influence of boundary conditions on the elastic response of the sandwich plate is shown.