3D crack initiation and propagation applied to metal forming processes
Source abstract
Abstract
Numerical simulation of ductile fracture in the field of metal forming represents one of the most challenging tasks. Throughout the chain of manufacturing processes, the accurate prediction of the crack surfaces is essential for the quality of the final products. The application of a crack initiation and propagation algorithm known as CIPFAR is presented in order to model the complex ductile fracture processes. In addition, a phase field approach is coupled with a ductile damage criterion to simulate the transition from damage to fracture. The self-contact between crack faces is also modeled through the penalization method in order to prevent the penetration of crack faces. The presented algorithm serves as an efficient computational tool for the industrial purposes in terms of the robustness and quality of the obtained results. Comparisons are carried out with the classical element deletion method in order to show the ability of the new algorithm to tackle the issues of mesh dependency and volume loss.
Source: openaire · Quality: candidate unverified · Source record ↗
Research context
OpenAlex topics: Metal Forming Simulation Techniques · Metallurgy and Material Forming · Numerical methods in engineering
SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.
References (64)
Show source-provided references
1. Tekkaya AE, Bouchard P-O, Bruschi S, Tasan CC (2020) Damage in metal forming. CIRP Ann 69:600–62310.1016/j.cirp.2020.05.005 ↗
2. Bao Y, Wierzbicki T (2004) On fracture locus in the equivalent strain and stress triaxiality space. Int J Mech Sci 46:81–9810.1016/j.ijmecsci.2004.02.006 ↗
3. Lou Y, Yoon JW, Huh H (2014) Modeling of shear ductile fracture considering a changeable cut-off value for stress triaxiality. International Journal of Plasticity 54:56–8010.1016/j.ijplas.2013.08.006 ↗
4. Bouchard P-O, Bourgeon L, Fayolle S, Mocellin K (2011) An enhanced Lemaitre model formulation for materials processing damage computation. Int J Mater Form 4:299–31510.1007/s12289-010-0996-5 ↗
5. Cao T-S, Gachet J-M, Montmitonnet P, Bouchard P-O (2014) A Lode-dependent enhanced Lemaitre model for ductile fracture prediction at low stress triaxiality. Eng Fract Mech 124:80–9610.1016/j.engfracmech.2014.03.021 ↗
6. Cockcroft MG (1968) Ductility and workability of metals. Journal of Metals 96:2444
7. Johnson GR, Cook WH (1985) Fracture characteristics of three metals subjected to various strains, strain rates, temperatures and pressures. Eng Fract Mech 21:31–4810.1016/0013-7944(85)90052-9 ↗
8. Rice JR, Tracey DM (1969) On the ductile enlargement of voids in triaxial stress fields. Journal of the Mechanics and Physics of Solids 17:201–21710.1016/0022-5096(69)90033-7 ↗
9. Gurson AL (1977) Continuum theory of ductile rupture by void nucleation and growth: part 1-Yield criteria and flow rules for porous ductilr media. J Eng Mater Technol 99:2–1510.1115/1.3443401 ↗
10. Tvergaard V, Needleman A (1984) Analysis of the cup-cone fracture in a round tensile bar. Acta Metall 32:157–16910.1016/0001-6160(84)90213-X ↗
11. Murakami S, Ohno N (1981) A continuum theory of creep and creep damage. In: Creep in structures, Springer, pp 422–44410.1007/978-3-642-81598-0_28 ↗
12. Kachanov LM (1999) Rupture time under creep conditions. Int J Fract 97:11–1810.1023/A:1018671022008 ↗
13. Lemaitre J, Desmorat R (2005) Engineering damage mechanics: ductile, creep, fatigue and brittle failures. Springer Science & Business Media
14. Yue Z, Cao K, Badreddine H, Saanouni K, Gao J (2019) Failure prediction on steel sheet under different loading paths based on fully coupled ductile damage model. Int J Mech Sci 153:1–910.1016/j.ijmecsci.2019.01.029 ↗
15. Jirásek M (2007) Mathematical analysis of strain localization. Revue européenne de génie civil 11:977–99110.1080/17747120.2007.9692973 ↗
16. Peerlings RHJ, Borst Rd, Brekelmans Wd, Vree Jd, Spee I (1996) Some observations on localization in non-local and gradient damage models. European Journal of Mechanics. A Solids 15:937–953
17. Peerlings RHJ, de Borst R, Brekelmans WM, De Vree J (1996) Gradient enhanced damage for quasi-brittle materials. Int J Numer Methods Eng 39:3391–340310.1002/(SICI)1097-0207(19961015)39:19<3391::AID-NME7>3.0.CO;2-D ↗
18. Saanouni K, Hamed M (2013) Micromorphic approach for finite gradient-elastoplasticity fully coupled with ductile damage: Formulation and computational aspects. Int J Solids Struct 50:2289–230910.1016/j.ijsolstr.2013.03.027 ↗
19. Cao T-S (2014) Numerical simulation of 3D ductile cracks formation using recent improved Lode-dependent plasticity and damage models combined with remeshing. Int J Solids Struct 51:2370–238110.1016/j.ijsolstr.2014.03.005 ↗
20. Saanouni K, Mariage J-F, Cherouat A, Lestriez P (2004) Numerical prediction of discontinuous central bursting in axisymmetric forward extrusion by continuum damage mechanics. Computers & Structures 82:2309–233210.1016/j.compstruc.2004.05.018 ↗
21. Labergere C, Rassineux A, Saanouni K (2014) Numerical simulation of continuous damage and fracture in metal-forming processes with 2D mesh adaptive methodology. Finite Elem Anal Des 82:46–6110.1016/j.finel.2013.12.004 ↗
22. Yang F, Rassineux A, Labergere C, Saanouni K (2018) A 3D h-adaptive local remeshing technique for simulating the initiation and propagation of cracks in ductile materials. Comput Methods Appl Mech Eng 330:102–12210.1016/j.cma.2017.10.012 ↗
23. Niu L-B, Takaku H, Kobayashi M (2005) Tensile fracture behaviors in double-notched thin plates of a ductile steel. ISIJ International 45:281–28710.2355/isijinternational.45.281 ↗
24. El Khaoulani R, Bouchard P-O (2012) An anisotropic mesh adaptation strategy for damage and failure in ductile materials. Finite Elem Anal Des 59:1–1010.1016/j.finel.2012.04.006 ↗
25. Hambli R (2002) Prediction of burr height formation in blanking processes using neural network. Int J Mech Sci 44:2089–210210.1016/S0020-7403(02)00168-6 ↗
26. Komori K (1999) Simulation of chevron crack formation and evolution in drawing. Int J Mech Sci 41:1499–151310.1016/S0020-7403(98)00101-5 ↗
27. Mediavilla J, Peerlings RHJ, Geers MGD (2006) Discrete crack modelling of ductile fracture driven by non-local softening plasticity. Int J Numer Methods Eng 66:661–68810.1002/nme.1572 ↗
28. Feld-Payet S, Chiaruttini V, Besson J, Feyel F (2015) A new marching ridges algorithm for crack path tracking in regularized media. Int J Solids Struct 71:57–6910.1016/j.ijsolstr.2015.04.043 ↗
29. Francfort GA, Marigo J-J (1998) Revisiting brittle fracture as an energy minimization problem. Journal of the Mechanics and Physics of Solids 46:1319–134210.1016/S0022-5096(98)00034-9 ↗
30. Ambrosio L, Tortorelli VM (1990) Approximation of functional depending on jumps by elliptic functional via t-convergence. Commun Pur Appl Math 43:999–103610.1002/cpa.3160430805 ↗
31. Braides A (1998) Approximation of free-discontinuity problems. Springer Science & Business Media10.1007/BFb0097344 ↗
32. Miehe C, Welschinger F, Hofacker M (2010) Thermodynamically consistent phase-field models of fracture: Variational principles and multi-field FE implementations. Int J Numer Methods Eng 83:1273–131110.1002/nme.2861 ↗
33. Miehe C, Hofacker M, Welschinger F (2010) A phase field model for rate-independent crack propagation: Robust algorithmic implementation based on operator splits. Comput Methods Appl Mech Eng 199:2765–277810.1016/j.cma.2010.04.011 ↗
34. Ambati M, Gerasimov T, De Lorenzis L (2015) Phase-field modeling of ductile fracture. Comput Mech 55:1017–104010.1007/s00466-015-1151-4 ↗
35. Borden MJ, Hughes TJR, Landis CM, Anvari A, Lee IJ (2016) A phase-field formulation for fracture in ductile materials: Finite deformation balance law derivation, plastic degradation, and stress triaxiality effects. Comput Methods Appl Mech Eng 312:130–16610.1016/j.cma.2016.09.005 ↗
36. Eldahshan H, Alves J, Bouchard P-O, Perchat E, Munoz DP (2021) CIPFAR: A 3D unified numerical framework for the modeling of ductile fracture based on the phase field model and adaptive remeshing. Comput Methods Appl Mech Eng 387:11417110.1016/j.cma.2021.114171 ↗
37. Griffith AA (1921) The phenomena of rupture and flow in solids. Philosophical Transactions of the Royal Society of London. 221:163–19810.1098/rsta.1921.0006 ↗
38. Miehe C, Hofacker M, Schänzel L-M, Aldakheel F (2015) Phase field modeling of fracture in multi-physics problems. Part II. Coupled brittle-to-ductile failure criteria and crack propagation in thermo-elastic–plastic solids. Comput Methods Appl Mech Eng 294:486–52210.1016/j.cma.2014.11.017 ↗
39. Needleman A (1988) Material rate dependence and mesh sensitivity in localization problems. Comput Methods Appl Mech Eng 67:69–8510.1016/0045-7825(88)90069-2 ↗
40. Mühlhaus H-B, Alfantis E (1991) A variational principle for gradient plasticity. Int J Solids Struct 28:845–85710.1016/0020-7683(91)90004-Y ↗
41. Forest S (2009) Micromorphic approach for gradient elasticity, viscoplasticity, and damage. J Eng Mech 135:117–13110.1061/(ASCE)0733-9399(2009)135:3(117) ↗
42. Lemaitre J (1985) A continuous damage mechanics model for ductile fracture. J Eng Mater Technol 107:83–8910.1115/1.3225775 ↗
43. Reusch F, Svendsen B, Klingbeil D (2003) Local and non-local Gurson-based ductile damage and failure modelling at large deformation. European Journal of Mechanics-A/Solids 22:779–79210.1016/S0997-7538(03)00070-6 ↗
44. Ambati M, Gerasimov T, De Lorenzis L (2015) A review on phase-field models of brittle fracture and a new fast hybrid formulation. Comput Mech 55:383–40510.1007/s00466-014-1109-y ↗
45. Alessi R, Ambati M, Gerasimov T, Vidoli S, De Lorenzis L (2018) Comparison of phase-field models of fracture coupled with plasticity. In: Advances in computational plasticity, Springer, pp 1–2110.1007/978-3-319-60885-3_1 ↗
46. de Borst R, Verhoosel CV (2016) Gradient damage vs phase-field approaches for fracture: Similarities and differences. Comput Methods Appl Mech Eng 312:78–9410.1016/j.cma.2016.05.015 ↗
47. Geers MGD, De Borst R, Brekelmans WAM, Peerlings RHJ (1998) Strain-based transient-gradient damage model for failure analyses. Comput Methods Appl Mech Eng 160:133–15310.1016/S0045-7825(98)80011-X ↗
48. Geers MGD (1998) Experimental analysis and computational modelling of damage and fracture. Ph.D. thesis, Eindhoven Technical university
49. Eldahshan H, Bouchard P-O, Alves J, Perchat E, Munoz DP (2021) Phase field modeling of ductile fracture at large plastic strains using adaptive isotropic remeshing. Comput Mech, pp 1–2110.1007/s00466-020-01962-7 ↗
50. Davaze V, Vallino N, Langrand B, Besson J, Feld-Payet S (2021) A non-local damage approach compatible with dynamic explicit simulations and parallel computing. International Journal of Solids and Structures10.1016/j.ijsolstr.2021.02.010 ↗
51. Aldakheel F, Wriggers P, Miehe C (2018) A modified Gurson-type plasticity model at finite strains: formulation, numerical analysis and phase-field coupling. Comput Mech 62:815–83310.1007/s00466-017-1530-0 ↗
52. Eberly D, Gardner R, Morse B, Pizer S, Scharlach C (1994) Ridges for image analysis. Journal of Mathematical Imaging and Vision 4:353–37310.1007/BF01262402 ↗
53. Amor H, Marigo J-J, Maurini C (2009) Regularized formulation of the variational brittle fracture with unilateral contact: Numerical experiments. Journal of the Mechanics and Physics of Solids 57:1209–122910.1016/j.jmps.2009.04.011 ↗
54. Fei F, Choo J (2020) A phase-field method for modeling cracks with frictional contact. Int J Numer Methods Eng 121:740–76210.1002/nme.6242 ↗
55. Goldsmith J, Salmon J (1987) Automatic creation of object hierarchies for ray tracing. IEEE Comput Graph Appl 7:14–2010.1109/MCG.1987.276983 ↗
56. Benson DJ, Hallquist JO (1990) A single surface contact algorithm for the post-buckling analysis of shell structures. Comput Methods Appl Mech Eng 78:141–16310.1016/0045-7825(90)90098-7 ↗
57. De Lorenzis L, Wriggers P, Weißenfels C (2017) Computational contact mechanics with the finite element method, Encyclopedia of Computational Mechanics Second Edition, pp 1–4510.1002/9781119176817.ecm2033 ↗
58. Hachani M, Fourment L (2013) A smoothing procedure based on quasi-C1 interpolation for 3D contact mechanics with applications to metal forming. Computers & Structures 128:1–1310.1016/j.compstruc.2013.05.008 ↗
59. Choi J-S, Lee H-C, Im Y-T (2010) A study on chevron crack formation and evolution in a cold extrusion. J Mech Sci Technol 24:1885–189010.1007/s12206-010-0605-z ↗
60. Husson C, Correia J, Daridon L, Ahzi S (2008) Finite elements simulations of thin copper sheets blanking: Study of blanking parameters on sheared edge quality. J Mater Process Technol 199:74–8310.1016/j.jmatprotec.2007.08.034 ↗
61. Hambli R, Potiron A (2000) Finite element modeling of sheet-metal blanking operations with experimental verification. J Mater Process Technol 102:257–26510.1016/S0924-0136(00)00496-9 ↗
62. de Sá JC, Areias P, Zheng C (2006) Damage modelling in metal forming problems using an implicit non-local gradient model. Comput Methods Appl Mech Eng 195:6646–666010.1016/j.cma.2005.02.037 ↗
63. Hambli R (2001) Comparison between Lemaitre and Gurson damage models in crack growth simulation during blanking process. Int J Mech Sci 43:2769–279010.1016/S0020-7403(01)00070-4 ↗
64. Kumar S, Fourment L, Guerdoux S (2015) Parallel, second-order and consistent remeshing transfer operators for evolving meshes with superconvergence property on surface and volume. Finite Elem Anal Des 93:70–8410.1016/j.finel.2014.09.002 ↗