Design sensitivity analysis in large deformation elasto‐plastic and elasto‐viscoplastic problems

Implicit time integration algorithm derived by Simo for his large‐deformation elasto‐plastic constitutive model is generalized, for the case of isotropy and associative flow rule, towards viscoplastic material behaviour and consistently differentiated with respect to its input parameters. Combining it with the general formulation of design sensitivity analysis (DSA) for non‐linear finite element transient equilibrium problem, we come at a numerically efficient, closed‐form finite element formulation of DSA for large deformation elasto‐plastic and elasto‐viscoplastic problems, with various types of design variables (material constants, shape parameters). The paper handles several specific issues, like the use of a non‐algorithmic coefficient matrix or sensitivity discontinuities at points of instantaneous structural stiffness change. Computational examples demonstrate abilities of the formulation and quality of results. Copyright © 2005 John Wiley & Sons, Ltd.     

Elasto‐plastic finite element analysis of shells with damage due to microvoids

This paper presents a non‐linear finite element analysis for the elasto‐plastic behaviour of thick/thin shells and plates with large rotations and damage effects. The refined shell theory given by Voyiadjis and Woelke (Int. J. Solids Struct. 2004; 41 :3747–3769) provides a set of shell constitutive equations. Numerical implementation of the shell theory leading to the development of the C⁰ quadrilateral shell element (Woelke and Voyiadjis, Shell element based on the refined theory for thick spherical shells. 2006, submitted) is used here as an effective tool for a linear elastic analysis of shells. The large rotation elasto‐plastic model for shells presented by Voyiadjis and Woelke (General non‐linear finite element analysis of thick plates and shells. 2006, submitted) is enhanced here to account for the damage effects due to microvoids, formulated within the framework of a micromechanical damage model. The evolution equation of the scalar porosity parameter as given by Duszek‐Perzyna and Perzyna (Material Instabilities: Theory and Applications, ASME Congress, Chicago, AMD‐Vol. 183/MD‐50, 9–11 November 1994; 59–85) is reduced here to describe the most relevant damage effects for isotropic plates and shells, i.e. the growth of voids as a function of the plastic flow. The anisotropic damage effects, the influence of the microcracks and elastic damage are not considered in this paper. The damage modelled through the evolution of porosity is incorporated directly into the yield function, giving a generalized and convenient loading surface expressed in terms of stress resultants and stress couples. A plastic node method (Comput. Methods Appl. Mech. Eng. 1982; 34 :1089–1104) is used to derive the large rotation, elasto‐plastic‐damage tangent stiffness matrix. Some of the important features of this paper are that the elastic stiffness matrix is derived explicitly, with all the integrals calculated analytically (Woelke and Voyiadjis, Shell element based on the refined theory for thick spherical shells. 2006, submitted). In addition, a non‐layered model is adopted in which integration through the thickness is not necessary. Consequently, the elasto‐plastic‐damage stiffness matrix is also given explicitly and numerical integration is not performed. This makes this model consistent mathematically, accurate for a variety of applications and very inexpensive from the point of view of computer power and time. Copyright © 2006 John Wiley & Sons, Ltd.     

Experimental and numerical studies on size and constraining effects in lead-free solder joints

The durability and reliability of lead‐free solder joints depends on a large number of factors, like geometry, processing parameters, microstructure and thermomechanical loads. In this work, the nature and influence of the plastic constraints in the solder due to joining partners have been studied by parametric finite element simulation of solder joints with different dimensions. The apparent hardening due to plastic constraints has been shown to strongly depend on the solder gap to thickness ratio with an inversely proportional evolution. Due to interaction of several parameters, the macroscopic stress–strain constitutive law of lead‐free solder materials should be determined in the most realistic conditions. In order to identify the elasto‐plastic constitutive law of Sn–Ag–Cu solders, a sub‐micron resolution Digital Image Correlation technique has been developed to measure the evolution of strain in solder joints during a tensile test. Experimental results of the stress–strain response of Sn–Ag–Cu solder joints have been determined for several solder gaps. The measured load–displacement curves have been used in an inverse numerical identification procedure to determine the constitutive elasto‐plastic behaviour of the solder material. The effects of geometrical constraints in a real solder joint with heterogeneous stress and strain fields are then studied by comparing the apparent (constrained) and constitutive (non‐constrained) stress–strain relationships. Once the size dependant constraining effects have been removed from the stress–strain relationship, the scale effects can be studied separately by comparing the constitutive elasto‐plastic parameters of joints with a variable thickness. Experimental stress–strain curves (constrained and unconstrained) for Sn–4.0Ag–0.5Cu solder in joints of 0.25–2.4 mm gap are presented and the constraining and the size effects are discussed.     

A non‐linear interface element for 3D mesoscale analysis of brick‐masonry structures

This paper presents a novel interface element for the geometric and material non‐linear analysis of unreinforced brick‐masonry structures. In the proposed modelling approach, the blocks are modelled using 3D continuum solid elements, whereas the mortar and brick–mortar interfaces are modelled by means of the 2D non‐linear interface element. This enables the representation of any 3D arrangement for brick‐masonry, accounting for the in‐plane stacking mode and the through‐thickness geometry, and importantly it allows the investigation of both the in‐plane and the out‐of‐plane responses of unreinforced masonry panels. A co‐rotational approach is employed for the interface element, which shifts the treatment of geometric non‐linearity to the level of discrete entities, and enables the consideration of material non‐linearity within a simplified local framework employing first‐order kinematics. In this respect, the internal interface forces are modelled by means of elasto‐plastic material laws based on work‐softening plasticity and employing multi‐surface plasticity concepts. Following the presentation of the interface element formulation details, several experimental–numerical comparisons are provided for the in‐plane and out‐of‐plane static behaviours of brick‐masonry panels. The favourable results achieved demonstrate the accuracy and the significant potential of using the developed interface element for the non‐linear analysis of brick‐masonry structures under extreme loading conditions. Copyright © 2010 John Wiley & Sons, Ltd.     

On the design of energy–momentum integration schemes for arbitrary continuum formulations. Applications to classical and chaotic motion of shells

The construction of energy–momentum methods depends heavily on three kinds of non‐linearities: (1) the geometric (non‐linearity of the strain–displacement relation), (2) the material (non‐linearity of the elastic constitutive law), and (3) the one exhibited in displacement‐dependent loading. In previous works, the authors have developed a general method which is valid for any kind of geometric non‐linearity. In this paper, we extend the method and combine it with a treatment of material non‐linearity as well as that exhibited in force terms. In addition, the dynamical formulation is presented in a general finite element framework where enhanced strains are incorporated as well. The non‐linearity of the constitutive law necessitates a new treatment of the enhanced strains in order to retain the energy conservation property. Use is made of the logarithmic strain tensor which allows for a highly non‐linear material law, while preserving the advantage of considering non‐linear vibrations of classical metallic structures. Various examples and applications to classical and non‐classical vibrations and non‐linear motion of shells are presented, including (1) chaotic motion of arches, cylinders and caps using a linear constitutive law and (2) large overall motion and non‐linear vibration of shells using non‐linear constitutive law. Copyright © 2004 John Wiley & Sons, Ltd.     

Numerical implementation of a neural network based material model in finite element analysis

Neural network (NN) based constitutive models can capture non‐linear material behaviour. These models are versatile and have the capacity to continuously learn as additional material response data becomes available. NN constitutive models are increasingly used within the finite element (FE) method for the solution of boundary value problems. NN constitutive models, unlike commonly used plasticity models, do not require special integration procedures for implementation in FE analysis. NN constitutive model formulation does not use a material stiffness matrix concept in contrast to the elasto‐plastic matrix central to conventional plasticity based models. This paper addresses numerical implementation issues related to the use of NN constitutive models in FE analysis. A consistent material stiffness matrix is derived for the NN constitutive model that leads to efficient convergence of the FE Newton iterations. The proposed stiffness matrix is general and valid regardless of the material behaviour represented by the NN constitutive model. Two examples demonstrate the performance of the proposed NN constitutive model implementation. Copyright © 2004 John Wiley & Sons, Ltd.     

New development in extended finite element modeling of large elasto‐plastic deformations

This paper presents new achievements in the extended finite element modeling of large elasto‐plastic deformation in solid problems. The computational technique is presented based on the extended finite element method (X‐FEM) coupled with the Lagrangian formulation in order to model arbitrary interfaces in large deformations. In X‐FEM, the material interfaces are represented independently of element boundaries, and the process is accomplished by partitioning the domain with some triangular sub‐elements whose Gauss points are used for integration of the domain of elements. The large elasto‐plastic deformation formulation is employed within the X‐FEM framework to simulate the non‐linear behavior of materials. The interface between two bodies is modeled by using the X‐FEM technique and applying the Heaviside‐ and level‐set‐based enrichment functions. Finally, several numerical examples are analyzed, including arbitrary material interfaces, to demonstrate the efficiency of the X‐FEM technique in large plasticity deformations. Copyright © 2008 John Wiley & Sons, Ltd.     

A meshless grain element for micromechanical analysis with crystal plasticity

This study concerns the development of a 2‐D meshless grain element for elasto‐plastic deformation and intergranular damage initiation and propagation in polycrystalline fcc metals under static loading. The crystallographic material behaviour of the grains is represented by a rate‐independent single‐crystal plasticity model while including material orthotropy. The two slip planes are arbitrarily located with respect to the crystallographic axis of the grain. A non‐linear constitutive model known as the cohesive zone model is employed to represent the inelastic interaction between the grain boundaries, thus permitting grain boundary opening and sliding. The cohesive model describes the deformation characteristics of the grain boundaries through a non‐linear relation between the effective grain boundary tractions and displacements. Because of the presence of non‐linear material behaviour both inside the grain and along the cohesive grain boundaries, the method utilizes the principle of virtual work in conjunction with the meshless formulation in the derivation of the system of non‐linear incremental equilibrium equations. The solution is obtained via an incremental procedure based on the Taylor series expansion about the current equilibrium configuration. The fidelity of the present approach is verified by considering simple polycrystalline metals of only a few grains. Copyright © 2006 John Wiley & Sons, Ltd.     

Mixed finite element method for coupled thermo‐hydro‐mechanical process in poro‐elasto‐plastic media at large strains

A mixed finite element for coupled thermo‐hydro‐mechanical (THM) analysis in unsaturated porous media is proposed. Displacements, strains, the net stresses for the solid phase; pressures, pressure gradients, Darcy velocities for pore water and pore air phases; temperature, temperature gradients, the total heat flux are interpolated as independent variables. The weak form of the governing equations of coupled THM problems in porous media within the element is given on the basis of the Hu–Washizu three‐filed variational principle. The proposed mixed finite element formulation is derived. The non‐linear version of the element formulation is further derived with particular consideration of the THM constitutive model for unsaturated porous media based on the CAP model. The return mapping algorithm for the integration of the rate constitutive equation, the consistent elasto‐plastic tangent modulus matrix and the element tangent stiffness matrix are developed. For geometrical non‐linearity, the co‐rotational formulation approach is utilized. Numerical results demonstrate the capability and the performance of the proposed element in modelling progressive failure characterized by strain localization and the softening behaviours caused by thermal and chemical effects. Copyright © 2005 John Wiley & Sons, Ltd.     

Enhanced transverse shear strain shell formulation applied to large elasto‐plastic deformation problems

In this work, a previously proposed Enhanced Assumed Strain (EAS) finite element formulation for thin shells is revised and extended to account for isotropic and anisotropic material non‐linearities. Transverse shear and membrane‐locking patterns are successfully removed from the displacement‐based formulation. The resultant EAS shell finite element does not rely on any other mixed formulation, since the enhanced strain field is designed to fulfil the null transverse shear strain subspace coming from the classical degenerated formulation. At the same time, a minimum number of enhanced variables is achieved, when compared with previous works in the field. Non‐linear effects are treated within a local reference frame affected by the rigid‐body part of the total deformation. Additive and multiplicative update procedures for the finite rotation degrees‐of‐freedom are implemented to correctly reproduce mid‐point configurations along the incremental deformation path, improving the overall convergence rate. The stress and strain tensors update in the local frame, together with an additive treatment of the EAS terms, lead to a straightforward implementation of non‐linear geometric and material relations. Accuracy of the implemented algorithms is shown in isotropic and anisotropic elasto‐plastic problems. Copyright © 2004 John Wiley & Sons, Ltd.     

On the computation of design derivatives for Huber–Mises plasticity with non‐linear hardening

This paper concerns design sensitivity analysis (DSA) for an elasto–plastic material, with material parameters depending on, or serving as, design variables. The considered constitutive model is Huber–Mises deviatoric plasticity with non‐linear isotropic/kinematic hardening, one which is applicable to metals. The standard radial return algorithm for linear hardening is generalized to account for non‐linear hardening functions. Two generalizations are presented; in both the non‐linearity is treated iteratively, but the iteration loop contains either a scalar equation or a group of tensorial equations. It is proven that the second formulation, which is the one used in some parallel codes, can be equivalently brought to a scalar form, more suitable for design differentiation. The design derivatives of both the algorithms are given explicitly, enabling thus calculation of the ‘explicit’ design derivative of stresses entering the global sensitivity equation. The paper addresses several issues related to the implementation and testing of the DSA module; among them the concept of verification tests, both outside and inside a FE code, as well as the data handling implied by the algorithm. The numerical tests, which are used for verification of the DSA module, are described. They shed light on (a) the accuracy of the design derivatives, by comparison with finite difference computations and (b) the effect of the finite element formulation on the design derivatives for an isochoric plastic flow. Copyright © 2003 John Wiley & Sons, Ltd.     

Lower‐bound limit analysis by using the EFG method and non‐linear programming

Intended to avoid the complicated computations of elasto‐plastic incremental analysis, limit analysis is an appealing direct method for determining the load‐carrying capacity of structures. On the basis of the static limit analysis theorem, a solution procedure for lower‐bound limit analysis is presented firstly, making use of the element‐free Galerkin (EFG) method rather than traditional numerical methods such as the finite element method and boundary element method. The numerical implementation is very simple and convenient because it is only necessary to construct an array of nodes in the domain under consideration. The reduced‐basis technique is adopted to solve the mathematical programming iteratively in a sequence of reduced self‐equilibrium stress subspaces with very low dimensions. The self‐equilibrium stress field is expressed by a linear combination of several self‐equilibrium stress basis vectors with parameters to be determined. These self‐equilibrium stress basis vectors are generated by performing an equilibrium iteration procedure during elasto‐plastic incremental analysis. The Complex method is used to solve these non‐linear programming sub‐problems and determine the maximal load amplifier. Numerical examples show that it is feasible and effective to solve the problems of limit analysis by using the EFG method and non‐linear programming. Copyright © 2007 John Wiley & Sons, Ltd.     

A full‐discontinuous Galerkin formulation of nonlinear Kirchhoff–Love shells: elasto‐plastic finite deformations,parallel computation,and fracture applications

Because of its ability to take into account discontinuities, the discontinuous Galerkin (DG) method presents some advantages for modeling cracks initiation and propagation. This concept has been recently applied to three‐dimensional simulations and to elastic thin bodies. In this last case, the assumption of small elastic deformations before cracks initiation or propagation reduces drastically the applicability of the framework to a reduced number of materials. To remove this limitation, a full‐DG formulation of nonlinear Kirchhoff–Love shells is presented and is used in combination with an elasto‐plastic finite deformations model. The results obtained by this new formulation are in agreement with other continuum elasto‐plastic shell formulations. Then, this full‐DG formulation of Kirchhoff–Love shells is coupled with the cohesive zone model to perform thin body fracture simulations. As this method considers elasto‐plastic constitutive laws in combination with the cohesive model, accurate results compared with the experiments are found. In particular, the crack path and propagation rate of a blasted cylinder are shown to match experimental results. One of the main advantages of this framework is its ability to run in parallel with a high speed‐up factor, allowing the simulation of ultra fine meshes. Copyright © 2012 John Wiley & Sons, Ltd.     

工程结构分析新理论及其应用

本文将第一作者于１９８３年提出的双剪强度理论和１９９０年提出的统一强度理论推广为涵义更广的统一强度理论弹塑性本构模型，并将它们在计算机程序中实现，应用于结构弹塑性分析。统一强度理论及其弹塑性本构模型和相应的统一弹塑性计算程序，包含了现有的各种主要强度理论和新的可能的强度理论，它可以适用于范围十分广泛的各种工程材料和工程结构的弹塑性分析和塑性极限分析，它们的工程应用还能取得较大的经济效益，即更有效地发挥材料的强度潜力和节省工程投资。     

A three‐invariant hardening plasticity for numerical simulation of powder forming processes via the arbitrary Lagrangian–Eulerian FE model

In this paper, a three‐invariant cap plasticity model with an isotropic hardening rule is presented for numerical simulation of powder compaction processes. A general form is developed for single‐cap plasticity which can be compared with some common double‐surface plasticity models proposed for powders in literature. The constitutive elasto‐plastic matrix and its components are derived based on the definition of yield surface, hardening parameter and non‐linear elastic behaviour, as function of relative density of powder. Different aspects of the new single plasticity are illustrated by generating the classical plasticity models as special cases of the proposed model. The procedure for determination of powder parameters is described by fitting the model to reproduce data from triaxial compression and confining pressure experiments. The three‐invariant cap plasticity is performed within the framework of an arbitrary Lagrangian–Eulerian formulation, in order to predict the non‐uniform relative density distribution during large deformation of powder die pressing. In ALE formulation, the reference configuration is used for describing the motion, instead of material configuration in Lagrangian, and spatial configuration in Eulerian formulation. This formulation introduces some convective terms in the finite element equations and consists of two phases. Each time step is analysed according to Lagrangian phase until required convergence is attained. Then, the Eulerian phase is applied to keep mesh configuration regular. Because of relative displacement between mesh and material, all dependent variables such as stress and strain are converted through the Eulerian phase. Finally, the numerical schemes are examined for efficiency and accuracy in the modelling of a rotational flanged component, an automotive component, a conical shaped‐charge liner and a connecting‐rod. Copyright © 2005 John Wiley & Sons, Ltd.     

Hyper‐reduction of mechanical models involving internal variables

We propose to improve the efficiency of the computation of the reduced‐state variables related to a given reduced basis. This basis is supposed to be built by using the snapshot proper orthogonal decomposition (POD) model reduction method. In the framework of non‐linear mechanical problems involving internal variables, the local integration of the constitutive laws can dramatically limit the computational savings provided by the reduction of the order of the model. This drawback is due to the fact that, using a Galerkin formulation, the size of the reduced basis has no effect on the complexity of the constitutive equations. In this paper we show how a reduced‐basis approximation and a Petrov–Galerkin formulation enable to reduce the computational effort related to the internal variables. The key concept is a reduced integration domain where the integration of the constitutive equations is performed. The local computations being not made over the entire domain, we extrapolate the computed internal variable over the full domain using POD vectors related to the internal variables. This paper shows the improvement of the computational saving obtained by the hyper‐reduction of the elasto‐plastic model of a simple structure. Copyright © 2008 John Wiley & Sons, Ltd.     

Computational modeling of cardiac electrophysiology: A novel finite element approach

The key objective of this work is the design of an unconditionally stable, robust, efficient, modular, and easily expandable finite element‐based simulation tool for cardiac electrophysiology. In contrast to existing formulations, we propose a global–local split of the system of equations in which the global variable is the fast action potential that is introduced as a nodal degree of freedom, whereas the local variable is the slow recovery variable introduced as an internal variable on the integration point level. Cell‐specific excitation characteristics are thus strictly local and only affect the constitutive level. We illustrate the modular character of the model in terms of the FitzHugh–Nagumo model for oscillatory pacemaker cells and the Aliev–Panfilov model for non‐oscillatory ventricular muscle cells. We apply an implicit Euler backward finite difference scheme for the temporal discretization and a finite element scheme for the spatial discretization. The resulting non‐linear system of equations is solved with an incremental iterative Newton–Raphson solution procedure. Since this framework only introduces one single scalar‐valued variable on the node level, it is extremely efficient, remarkably stable, and highly robust. The features of the general framework will be demonstrated by selected benchmark problems for cardiac physiology and a two‐dimensional patient‐specific cardiac excitation problem. Copyright © 2009 John Wiley & Sons, Ltd.     

Elasto‐plastic deformation of upsetting by boundary element method

Abstract

This paper presents the utilization of boundary element method (BEM) to analyze the elasto‐plastic deformation of upsetting problems. Method of successive elastic solutions is used in the nonlinear analysis; both the linear strain hardening and the power law relation are used as constitutive equations of the material. For the later model the slope of strain hardening at each step is modified to a more correct prediction to make the deformation step larger and to obtain better convergence. The result may verify the stress‐strain curve as it does, and verify the similar pattern of the plastic zone propagation as Roll's result by finite element method. It is shown that various frictional conditions and width‐height ratios of the workpiece also influence the propagation behavior of plastic zones.     

Analysis on the fatigue damage evolution of notched specimens with consideration of cyclic plasticity

This paper presents a damage mechanics method applied successfully to assess fatigue life of notched specimens with plastic deformation at the notch tip. A damage‐coupled elasto‐plastic constitutive model is employed in which nonlinear kinematic hardening is considered. The accumulated damage is described by a stress‐based damage model and a plastic strain‐based damage model, which depend on the cyclic stress and accumulated plastic strain, respectively. A three‐dimensional finite element implementation of these models is developed to predict the crack initiation life of notched specimens. Two cases, a notched plate under tension‐compression loadings and an SAE notched shaft under bending‐torsion loadings including non‐proportional loadings, are studied and the predicted results are compared with experimental data.     

Finite element implementation of non‐linear elastoplastic constitutive laws using local and global explicit algorithms with automatic error control

Implicit stress integration algorithms have been demonstrated to provide a robust formulation for finite element analyses in computational mechanics, but are difficult and impractical to apply to increasingly complex non‐linear constitutive laws. This paper discusses the performance of fully explicit local and global algorithms with automatic error control used to integrate general non‐linear constitutive laws into a non‐linear finite element computer code. The local explicit stress integration procedure falls under the category of return mapping algorithm with standard operator split and does not require the determination of initial yield or the use of any form of stress adjustment to prevent drift from the yield surface. The global equations are solved using an explicit load stepping with automatic error control algorithm in which the convergence criterion is used to compute automatically the coarse load increment size. The proposed numerical procedure is illustrated here through the implementation of a set of elastoplastic constitutive relations including isotropic and kinematic hardening as well as small strain hysteretic non‐linearity. A series of numerical simulations confirm the robustness, accuracy and efficiency of the algorithms at the local and global level. Published in 2001 by John Wiley & Sons, Ltd.