Texture evolution and inhomogeneous deformation of polycrystalline Cu based on crystal plasticity finite element method and particle swarm optimization algorithm

Texture evolution and inhomogeneous deformation of polycrystalline Cu during uniaxial compression are investigated at the grain scale by combining crystal plasticity finite element method(CPFEM) with particle swarm optimization(PSO) algorithm. The texture-based representative volume element(TBRVE) is used in the crystal plasticity finite element model, where a given number of crystallographic orientations are obtained by means of discretizing the orientation distribution function(ODF) based on electron backscattered diffraction(EBSD) experiment data. Three-dimensional grains with different morphologies are generated on the basis of Voronoi tessellation. The PSO algorithm plays a significant role in identifying the material parameters and saving computational time. The macroscopic stress–strain curve is predicted based on CPFEM, where the simulation results are in good agreement with the experimental ones. Therefore, CPFEM is a powerful candidate for capturing the texture evolution and clarifying the inhomogeneous plastic deformation of polycrystalline Cu. The simulation results indicate that the <110> fiber texture is generated finally with the progression of plastic deformation. The inhomogeneous distribution of rotation angles lays the foundation for the inhomogeneous deformation of polycrystalline Cu in terms of grain scale.

Three-Dimensional Thermo-Elastic-Plastic Finite Element Method Modeling for Predicting Weld-Induced Residual Stresses and Distortions in Steel Stiffened-Plate Structures

The objective of the present paper is to develop nonlinear finite element method models for predicting the weld-induced initial deflection and residual stress of plating in steel stiffened-plate structures. For this purpose, three-dimensional thermo-elastic-plastic finite element method computations are performed with varying plate thickness and weld bead length (leg length) in welded plate panels, the latter being associated with weld heat input. The finite element models are verified by a comparison with experimental database which was obtained by the authors in separate studies with full scale measurements. It is concluded that the nonlinear finite element method models developed in the present paper are very accurate in terms of predicting the weld-induced initial imperfections of steel stiffened plate structures. Details of the numerical computations together with test database are documented.

Finite element modeling of the shaped charge jet and design of the reusable perforating gun

Finite element method is used to study the formations of the penetration jet,the bulge,and the burr in the designed reusable perforating gun.The attached layer of the soft metal on the perforator is studied for the controlling of the bulge height on the casing of the reusable perforating gun.Results indicate that the shaped charge jet is initially formed in the center of the shaped charge liner and then the material of the liner is driven to the centerline of the liner by the detonation wave.The attachment of the soft metal layer to the cartridge of the perforator can be beneficial to control the bulge height.The design on the blind holes on the casing can affect the burr height formed by the collision between the jet and the casing.With the increase in the liner angle,the penetration width on the cement wall of the wellbore is increased.

Simulation of polycrystalline aluminum tensile test with crystal plasticity finite element method

The crystal plasticity was implemented in the finite element method(FEM) software ABAQUS through the user subroutine UMAT. By means of discretizing the space at the grain level with the Voronoi diagram method, a polycrystal model was built and used in the FEM analysis. The initial orientation of each grain was generated based on the orientation distribution function(ODF). The developed model was successfully applied in simulation of polycrystalline aluminium samples deformed by the tensile tests. The theoretical strain—stress relation was in good agreement with the experimental result. The simulation results show that the grain size has significant effect on the deformation behavior. The initial plastic deformation usually occurs at grain boundaries, and multiple slip often results in an enhanced local hardening at grain boundaries.

VARIATIONAL PRINCIPLES OF PERFORATED THIN PLATES AND FINITE ELEMENT METHOD FOR BUCKLING AND POST-BUCKLING ANALYSIS

On the basis of the general theory of perforated thin plates under large deflections, variational principles with deflection w and stress function F as variables are stated in detail.Based on these princi- ples,finite element method is established for analysing the buckling and post-buckling of perforated thin plates. It is found that the property of element is very complicated,owing to the multiple connexity of the region.

ANALYSIS OF ROLLING BY ELASTO-PLASTIC FINITE DEFORMATION CONTACT BOUNDARY ELEMENT METHOD

A multinonlinear boundary element method is established dealing with elasto plastic finite deformation contact problem, and it is employed to analysis rolling process. With rollers as elastic bodies, workpieces as elastio plastic bodies, rolling problem can be viewed as a frictional elasto plastic contact problem. With fewer assumptions in the simulation of the rolling process, a novel and accurate method is proposed for analysis of rolling problems.

RELIABILITY OF ELASTO-PLASTIC STRUCTURE USING FINITE ELEMENT METHOD

A solution of probabilistic FEM for elastic-plastic materials is presented based on the incremental theory of plasticity and a modified initial stress method. The formulations are deduced through a direct differentiation scheme. Partial differentiation of displacement, stress and the performance function can be iteratively performed with the computation of the mean values of displacement and stress. The presented method enjoys the efficiency of both the perturbation method and the finite difference method, but avoids the approximation during the partial differentiation calculation. In order to improve the efficiency, the adjoint vector method is introduced to calculate the differentiation of stress and displacement with respect to random variables. In addition, a time-saving computational method for reliability index of elastic-plastic materials is suggested based upon the advanced First Order Second Moment (FOSM) and by the usage of Taylor expansion for displacement. The suggested method is also applicable to 3-D cases.

Finite element analyses of slope stability problems using non-associated plasticity

In recent years, finite element analyses have increasingly been utilized for slope stability problems. In comparison to limit equilibrium methods, numerical analyses do not require any definition of the failure mechanism a priori and enable the determination of the safety level more accurately. The paper compares the performances of strength reduction finite element analysis(SRFEA) with finite element limit analysis(FELA), whereby the focus is related to non-associated plasticity. Displacement-based finite element analyses using a strength reduction technique suffer from numerical instabilities when using non-associated plasticity, especially when dealing with high friction angles but moderate dilatancy angles. The FELA on the other hand provides rigorous upper and lower bounds of the factor of safety(FoS) but is restricted to associated flow rules. Suggestions to overcome this problem, proposed by Davis(1968), lead to conservative FoSs; therefore, an enhanced procedure has been investigated. When using the modified approach, both the SRFEA and the FELA provide very similar results. Further studies highlight the advantages of using an adaptive mesh refinement to determine FoSs. Additionally, it is shown that the initial stress field does not affect the FoS when using a Mohr-Coulomb failure criterion.

RIGID FINITE ELEMENT AND LIMIT ANALYSIS

According to the lower-bound theorem of limit analysis the Rigid Finite Element Meth-od(RFEM)is applied to structural limit analysis and the linear programmings for limit analysis are deducedin this paper.Moreover,the Thermo-Parameter Method(TPM)and Parametric Variational principles(PVP)are used to reduce the computational effort while maintaining the accuracy of solutions.A better solution isalso obtained in this paper.

Three Dimension Rigid-plastic Finite Element Simulation for Two-Roll Cross-wedge Rolling Process

Cross-wedge rolling (CWR) is a metal process of ro ta ry forming. To produce a part, one cylindrical billet should be placed between t wo counterrotating and wedge-shape dies, which move tangentially relative each other. The billet suffers plastic deformation (essentially, localized compressio n) during its rotation between the rotating dies. Compared to other numerical si mulation methods, the finite element method (FEM) has advantages in solving gene ral problems with complex shapes of the formed parts. In cross-wedge rolling, t here are four stages in the workpiece deformation process, namely knifing, guidi ng, stretching and sizing stage. It is time-consuming and expensive to design t he CWR process by trial and error method. The application of numerical simul ation for the CWR process will help engineers to efficiently improve the process development. Tselikov, Hayama, Jain and Kobayashi, and Higashimo applied the sl ip-line theory in study of CWR process analysis. Zb.pater studied CWR process i ncluding upsetting by upper-bound method. The above numerical simulation were b ased on the two-dimensional plain-strain assumption ignored the metal flow in workpiece axial direction. Therefore, the complex three-dimensional stress and deformation involved in CWR processes were not presented. Compared to other nume rical simulation methods, the finite element method (FEM) has advantages in solv ing general problems with complex shapes of the formed parts. As yet, a few 3-D finite element simulation studies on CWR process have been reported in literatu res. In this paper, the process of cross wedge rolling (CWR) has been simulated and analyzed by 3D rigid-plastic finite element method. Considering the charact eristic of CWR, the static implicit FEM program is selected. The models proposed in this study uses the commercial code DEFORM 3D to simulate the CWR process. T his is an implicit Lagrangian finite element code, which includes many new enhan cements functions. A new method of utilizing multiple processors using the MPI s tandard has been implemented. Automatic switching between the two different defo rmation solvers (Sparse Solver and Conjugate Gradient Solver) has also been impl emented in order to increase the speed of simulations. In this paper, all stages in CWR process are simulated to be able to closely understand and analyze the a ctual CWR process. For simulating all forming stages in CWR process, the dynam ic adaptive remeshing technology for tetrahedral solid elements was applied. T he stress distributions in cross section of forming workpiece are analyzed to in terpret fracture or rarefaction in the center of workpiece. Authors also analyze d the time-torque curve and the laws of load changing.

Finite element analysis of slope stability by expanding the mobilized principal stress Mohr's circles-Development, encoding and validation

In recent years,finite element analysis is increasingly being proposed in slope stability problems as a competitive method to traditional limit equilibrium methods(LEMs)which are known for their inherent deficiencies.However,the application of finite element method(FEM)to slope stability as a strength reduction method(SRM)or as finite element limit analysis(FELA)is not always a success for the drawbacks that characterize both methods.To increase the performance of finite element analysis in this problem,a new approach is proposed in this paper.It consists in gradually expanding the mobilized stress Mohr’s circles until the soil failure occurs according to a prescribed non-convergence criterion.The present approach called stress deviator increasing method(SDIM)is considered rigorous for three main reasons.Firstly,it preserves the definition of the factor of safety(FOS)as the ratio of soil shear strength to the mobilized shear stress.Secondly,it maintains the progressive development of shear stress resulting from the increase in the principal stress deviator on the same plane,on which the shear strength takes place.Thirdly,by introducing the concept of equivalent stress loading,the resulting trial stresses are checked against the violation of the actual yield criterion formed with the real strength parameters rather than those reduced by a trial factor.The new numerical procedure was encoded in a Fortran computer code called S^(4)DINA and verified by several examples.Comparisons with other numerical methods such as the SRM,gravity increasing method(GIM)or even FELA by assessing both the FOS and contours of equivalent plastic strains showed promising results.

Finite element analysis of elasto-plastic plate bending problems using transition rectangular plate elements

In this work, the finite element analysis of the elasto-plastic plate bending problems is carried out using transition rectangular plate elements. The shape functions of the transition plate elements are derived based on a practical rule. The transition plate elements are all quadrilateral and can be used to obtain efficient finite element models using minimum number of elements. The mesh convergence rates of the models including the transition elements are compared with the regular element models. To verify the developed elements, simple tests are demonstrated and various elasto-plastic problems are solved. Their results are compared with ANSYS results.

Simulation of bulk metal forming processes using one-step finite element approach based on deformation theory of plasticity

The bulk metal forming processes were simulated by using a one-step finite element(FE)approach based on deformation theory of plasticity,which enables rapid prediction of final workpiece configurations and stress/strain distributions.This approach was implemented to minimize the approximated plastic potential energy derived from the total plastic work and the equivalent external work in static equilibrium,for incompressibly rigid-plastic materials,by FE calculation based on the extremum work principle.The one-step forward simulations of compression and rolling processes were presented as examples,and the results were compared with those obtained by classical incremental FE simulation to verify the feasibility and validity of the proposed method.

Investigation on ductile fracture in fine-blanking process by finite element method

In order to continuously analyze the whole fine-blanking process, from the beginning of the operation up to the total rupture of the sheet-metal, without computational divergence, a 3-D rigid visco-plastic finite-element method based on Gurson void model was developed. The void volume fraction was introduced into the finite element method to document the ductile fracture of the sheet-metal. A formulation of variation of the rigid visco-plastic material was presented according to the virtual work theory in which both the effects of equivalent stress and hydrostatic pressure in the deformation process were considered. The crack initiation of the sheet was predicted and the crack propagation was geometrically fulfilled in the simulation by separating the nodes according to the stress state. Furthermore, the influences of different state-variables on the deformation process were also studied.

PREDICTION FOR FORMING LIMIT OF AL2024T3 SHEET BASED ON DAMAGE THEORY USING FINITE ELEMENT METHOD

This paper presents the application of anisotropic damage theory to the study of forming limit diagram of A12024T3 aluminum alloy sheet. In the prediction of limiting strains of the aluminum sheet structure, a finite element cell model has been constructed. The cell model consists of two phases, the aluminum alloy matrix and the intermetallic cluster. The material behavior of the aluminum alloy matrix is described with a fully coupled elasto-plastic damage constitutive equation. The intermetallic cluster is assumed to be elastic and brittle. By varying the stretching ratio, the limiting strains of the sheet under biaxial stretching have been predicted by using the necking criterion proposed. The prediction is in good agreement with the experimental findings. Moreover, the finite element cell model can provide information for understanding the microscopic damage mechanism of the aluminum alloy. Over-estimation of the limit strains may result if the effect of material damage is ignored in the sheet metal forming study.

FINITE ELEMENT ANALYSIS OF SUBSTRATE LOCAL PLASTIC DEFORMATION INDUCED BY CRACKED THIN HARD FILM

It has been postulated that, with tensile loading conditions, micro-cracks onthin hard film act as stress concentrators enhancing plastic deformation of the substrate materialin their vicinity. Under favorable conditions the localized plastic flow near the cracks may turninto macroscopic plastic strain thus affects the plasticity behaviors of the substrate. Thisphenomenon is analyzed quantitatively with finite element method with special attention focused onthe analysis and discussion of the effects of plastic work hardening rate, film thickness and crackdepth on maximum plastic strain, critical loading stress and the size of the local plasticdeformation zone. Results show that micro-cracks on thin hard film have unnegligible effects on theplasticity behaviors of the substrate material under tensile loading.

EFFECTIVE NUMERICAL METHODS FOR ELASTO-PLASTIC CONTACT PROBLEMS WITH FRICTION

Several effective numerical methods for solving the elasto-plastic contact problems with friction are pres- ented.First,a direct substitution method is employed to impose the contact constraint conditions on condensed finite ele- ment equations,thus resulting in a reduction by half in the dimension of final governing equations.Second,an algorithm composed of contact condition probes and elasto-plastic iterations is utilized to solve the governing equation,which distinguishes two kinds of nonlinearities,and makes the solution unique.In addition,Positive-Negative Sequence Modifica- tion Method is used to condense the finite element equations of each substructure and an analytical integration is intro- duced to determine the elasto-plastic status after each time step or each iteration,hence the computational efficiency is en- hanced to a great extent.Finally,several test and practical examples are pressented showing the validity and versatility of these methods and algorithms.

NONLINEAR AND ELASTO-PLASTICITY CONSOLIDATION MODELS OF UNSATURATED SOIL AND APPLICATIONS

The non-linear constitutive model suggested by the authors and the Alonso's elasto-plasticity model of unsaturated soil modified by the authors are introduced into the consolidation theory of unsaturated soil proposed by CHEN Zheng-han, and the non-linear and the elasto-plasticity consolidation models of unsaturated soil are obtained. Programs related to the two consolidation models are designed, and a 2-D consolidation problem of unsaturated sail is solved using the programs, the consolidation process and the development of plastic;one under multi-grade bad are studied. The above research develops the consolidation theory of unsaturated soil to a new level.

A new numerical method for determining collapse load-carrying capacity of structure made of elasto-plastic material

Determination of collapse load-carrying capacity of elasto-plastic material is very important in designing structure.The problem is commonly solved by elasto-plastic finite element method(FEM).In order to deal with material nonlinear problem involving strain softening problem effectively,a new numerical method-damped Newton method was proposed.The iterative schemes are discussed in detail for pure equilibrium models.In the equilibrium model,the plasticity criterion and the compatibility of the strains are verified,and the strain increment and plastic factor are treated as independent unknowns.To avoid the stiffness matrix being singularity or condition of matrix being ill,a damping factor α was introduced to adjust the value of plastic consistent parameter automatically during the iterations.According to the algorithm,the nonlinear finite element program was complied and its numerical example was calculated.The numerical results indicate that this method converges very fast for both small load steps and large load steps.Compared with those results obtained by analysis and experiment,the predicted ultimate bearing capacity from the proposed method is identical.

Study on Plasticity Modification for Measuring High Residual Stress by Hole-Drilling Method

Hole-drilling method is a commonly used method for measuring residual stress. The calibration coefficients in ASTM E837-13 a would cause large errors due to the plasticity deformation of materials. In the study, calibration coefficients were modified in the plasticity deformation stage based on the distortion energy theory. The calibration experiment of calibration coefficients was simulated by the finite element model, and the plasticity modification formulas of 7075 aluminum alloy were obtained. From the results of uniaxial tensile loading test, the measuring errors of high residual stress are significantly reduced from-4.071%～53.440% to-5.140% ～ 0.609% after the plasticity modification. This work provides an effective way to expand the application of hole-drilling method.