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• A robust approach to model densification and crack formation in powder compaction processes

  J. Hernández, J. Oliver, J. Cante, . Weyler

  International Journal for Numerical Methods in Engineering (2011). Vol. 87 (8), pp. 735-767

  
  

  Abstract

  This paper deals with the question of how to efficiently integrate a constitutive model that describes the densification of powders and the potential formation of cracks in Powder Metallurgy (P/M) cold compaction processes. The analyzed model is a large strain, elastoplastic model of the Drucker–Prager/Cap type, refined to cover also the prediction of crack formation, and featuring non-conventional elements such as a density-dependent Von Mises yield surface; a parabolic plastic potential function for the Drucker–Prager envelope; and a softening law whose softening modulus is dependent on the level of densification. The employed integration procedure is a non-conventional hybrid or IMPLicit–EXplicit (IMPL-EX) scheme, whose essence is to solve explicitly for some variables and implicitly for others, with the peculiarity of the ‘explicit’ variables being but extrapolated values of the same quantities computed, at previous time steps, by means of a fully implicit scheme. The return-mapping equations stemming from this implicit scheme are solved using an unconditionally convergent, fractional step method-based iterative procedure. The performance of the IMPL-EX integration algorithm is critically assessed in two different situations: the densification of a cylindrical specimen, and the fracture process in a diametral compression test. Results obtained show conclusively that the proposed hybrid integration strategy offers an efficient solution to the trade-off between robustness and computational time requirements

  Abstract
  This paper deals with the question of how to efficiently integrate a constitutive model that describes the densification of powders and the potential formation of cracks in [...]

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• On the proper characterization of tooling motions and initial conditions in powder die compaction modeling

  J. Hernández, J. Cante, J. Oliver, R. Weyler

  Journal of Materials Processing Technology (2011). Vol. 211 (8), pp. 1348-1357

  
  

  Abstract

  The present paper is concerned with the finite element modeling of Powder Metallurgy (P/M) cold die compaction process. Rather than on material constitutive theories or on numerical algorithmic issues, attention is confined exclusively on an scarcely addressed issue in the P/M modeling literature: the proper characterization of the boundary (tooling motions) and initial conditions of the problem. A case study of the compaction of an axially symmetric multilevel adapter in an advanced CNC press machine is used to convey the relevance of the accurate representation of these input data in the quality of model predictions. It is shown that unawareness or deliberate simplification of apparently insignificant details in this respect may cause errors far overshadowing those introduced by deficiencies in either the constitutive model or in the corresponding algorithmic solution procedure. The discussion of this case study serves also to provide useful modeling guidelines; illustrate frequent difficulties, as the unavailability of some information when guessing starting conditions; and reveal subtle, yet relevant for modeling purposes, technical details of advanced CNC press machines.

  Abstract
  The present paper is concerned with the finite element modeling of Powder Metallurgy (P/M) cold die compaction process. Rather than on material constitutive theories or on [...]

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• Flow regime analyses during the filling stage in powder metallurgy processes: experimental study and numerical modelling

  J. Cante, M. Riera, J. Oliver, J. Prado

  Granular Matter (2011). Vol. 13 (1), pp. 79-92

  
  

  Abstract

  Experimental and numerical studies of powder flow during the die filling stage in powder metallurgy cold compaction processes are presented. An experimental setting consisting of a horizontal pneumatically activated shoe, a vertical die and high-speed video system has been designed. The experiments show the existence of three flow regimes: continuous, transitory and discrete, which are identified in terms of the particle size, the morphology and the speed of the shoe. In the continuous regime the powder flows in a progressive manner but in the discrete one some perturbations appear as a consequence of a shear band formation that forms discrete avalanches. A numerical model, based on a ratedependent constitutive model, via a flow formulation, and in the framework of the particle finite element method (PFEM) is also proposed. For the purpose of this study, the use of the PFEM assumes that the powder can be modelled as a continuous medium. The model, provided with the corresponding characterisation of the parameters, is able to capture the two fundamental phenomena observed during the filling process: (1) the irreversibility of most of the deformation experienced by the material and (2) the quick dissipation of the potential gravitatory energy of the granular system through the inter-particle friction processes, modelled by the plastic dissipation associated with the material model. Experimental and numerical results have been compared in order to study the viability of the proposed model

  Abstract
  Experimental and numerical studies of powder flow during the die filling stage in powder metallurgy cold compaction processes are presented. An experimental setting consisting [...]

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• Simulación numérica del proceso de fractura en concreto reforzado mediante la metodología de discontinuidades fuertes de continuo. Parte II: Aplicación a páneles sometidos a cortante

  D. Linero, J. Oliver, A. Huespe

  Ingeniería e investigación (2010). Vol. 30 (3), pp. 16-26

  
  

  Abstract

  En este trabajo se presentan los resultados de la simulación numérica del proceso de fractura en páneles de concreto reforzado sometidos a cortante, utilizando un modelo basado en la metodología de discontinuidades fuertes de continuo (CSDA) y la teoría de mezclas. La CSDA describe la localzación de la deformación y la formación de una discontinuidad asociada con la aparición de una fisura. En cambio, la teoría de mezclas representa el comportamiento de un material compuesto, constituido por una matriz de concreto simple y uno o dos paquetes de barras largas de acero de refuerzo. El comportamiento del concreto simple y el acero se representan mediante un modelo de daño bidimensional y un modelo de plasticidad unidimensional, respectivamente. El modelo se implementa en el método de los elementos finitos considerando estado plano de esfuerzos, deformaciones infinitesimales y cargas estáticas. Se simularon tres páneles reforzados en una o en dos direcciones, los cuales estaban y sometidos principalmente a fuerzas cortantes. Los resultados de la simulación numérica, como la respuesta estructural y el patrón de fisuración, fueron satisfactorios. // The numerical simulation results of the fracture process in reinforced concrete shear panels are presented in this work. The simulation used a model based on the continuum strong discontinuity approach (CSDA) and mixing theory. CSDA describes strain localization and formation of discontinuity associated with the appearance of a crack. On the other hand, mixing theory represents composite material behaviour which is formed by a simple concrete matrix and one or two bundles of long reinforcement bars. The behaviour of simple concrete and steel is represented by a two-dimensional damage model and one-dimensional plasticity model, respectively. The model has been implemented in the finite element method which considers plane stress, infinitesimal strain and static loads. Three panels are simulated, reinforced in one or two ways; they are mainly subjected to shear forces. The numerical simulation results as well as structural response and cracking patterns were satisfactory.

  Abstract
  En este trabajo se presentan los resultados de la simulación numérica del proceso de fractura en páneles de concreto reforzado sometidos a cortante, utilizando [...]

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• Simulación numérica del proceso de fractura en concreto reforzado mediante la metodología de discontinuidades fuertes de continuo. Parte I: formulación

  D. Linero, J. Oliver, A. Huespe

  Ingeniería e investigación (2010). Vol. 30 (2), pp. 5-15

  
  

  Abstract

  En general, las estructuras de concreto reforzado como vigas, columnas y muros están conformadas por entramados complejos de barras de acero embebidas en una matriz de concreto, las cuales exhiben múltiples fisuras ante la aplicación de cargas externas elevadas. Este artículo presenta la formulación de un modelo numérico cuyo objetivo es describir el proceso de fractura en elementos de concreto reforzado a partir de la fracción volumétrica del concreto y del acero. El modelo utiliza un campo enriquecido de la deformación para describir la formación y propagación de fisuras en un material compuesto, tal como lo establecen la metodología de discontinuidades fuertes de continuo y la teoría de mezclas. El material compuesto está constituido por una matriz de concreto y uno o dos paquetes de barras de acero ortogonales entre sí. El acero y el concreto se representan con modelos de plasticidad unidimensional y de daño escalar con tracción y compresión diferenciada, respectivamente. La acción pasador y los efectos del deslizamiento entre las barras y la matriz, se describen con modelos adicionales que relacionan el esfuerzo y la deformación de los materiales componentes. Finalmente, se concluye que el modelo propuesto se puede implementar con facilidad en el método de los elementos finitos, dado que permanecen muchas características del procedimiento numérico no lineal convencional. Asimismo, el modelo permite analizar el problema en la escala macroscópica, lo cual elude la construcción de mallas de elementos finitos de cada material componente y de sus efectos de interacción, reduciendo así el costo computacional. // Reinforced concrete structures generally refers to beams, columns and walls which are constituted by complex lattices of steel bars embedded in a concrete matrix, exhibiting multiple cracks due to high external loads. This paper presents the formulation of a numerical model aimed at describing the fracture process in reinforced concrete, from the volumetric ratio of concrete and steel. Crack formation and propagation in a composite material is described in the model by an enhanced strain field, such as that established in the continuum strong discontinuity approach and mixture theory. The composite material is constituted by a concrete matrix and one or two steel bar orthogonal packages. The steel and concrete are represented by a one-dimensional plasticity model and a scalar damage model having different tension and compression strength, respectively. The dowel action and the bond-slip effects between the bars and the matrix are described with additional models relating component material stress and strain. It is concluded that the proposed model can easily be implemented in the finite element method, due to several conventional nonlinear numerical process characteristics which remain. The model would also allow the problem to be analysed at macroscopic scale, thereby avoiding a finite element mesh having to be constructed for each component material and its interaction effects and reducing computational costs

  Abstract
  En general, las estructuras de concreto reforzado como vigas, columnas y muros están conformadas por entramados complejos de barras de acero embebidas en una matriz [...]

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• Mesoscopic model to simulate the mechanical behavior of reinforced concrete members affected by corrosion

  P. Sánchez, A. Huespe, J. Oliver, S. Toro

  International Journal of Solids and Structures (2010). Vol. 47 (5), pp. 559-570

  
  

  Abstract

  In this contribution, a finite element methodology devised to simulate the structural deterioration of corroded reinforced concrete members is presented. The proposed numerical strategy has the ability to reproduce many of the well-known (undesirable) mechanical effects induced by corrosion processes in the embedded steel bars, as for example: expansion of the reinforcements due to the corrosion product accumulation, damage and cracking patterns distribution in the surrounding concrete, degradation of steel–concrete bond stress transfer, net area reduction in the reinforcements and, mainly, the influence of all these mentioned mechanisms on the structural load carrying capacity predictions. At the numerical level, each component of the RC structure is represented by means of a suitable FE formulation. For the concrete, a cohesive model based on the Continuum Strong Discontinuity Approach (CSDA) is used. Steel bars are modeled by means of an elasto-plastic constitutive relation. The interface is simulated using contact-friction elements, with the friction degradation as a function of the degree of corrosion attack. Two different (and coupled) mesoscopic analyzes are considered in order to describe the main physical phenomena that govern the problem: (i) an analysis at the cross section level and (ii) an analysis at the structural member level. The resultant mechanical model can be used to simulate generalized reinforcement corrosion. Experimental and previous numerical results, obtained from the available literature, are used to validate the proposed strategy

  Abstract
  In this contribution, a finite element methodology devised to simulate the structural deterioration of corroded reinforced concrete members is presented. The proposed [...]

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• Numerical modeling of crack formation in powder forming processes

  J. Hernández, J. Oliver, J. Cante, R. Weyler

  International Journal of Solids and Structures (2011). Vol. 48 (2), pp. 292-316

  
  

  Abstract

  This paper presents a constitutive model describing the mechanical behavior of metal powders during (uniaxial) cold die compaction processes, placing special emphasis on the modeling of cracks formed during the ejection stage. The constitutive relationships are derived within the general framework of rate-independent, isotropic, finite strain elastoplasticity. The yield condition is determined by three surfaces intersecting non-smoothly in stress space, namely, an elliptical cap and the classical Von Mises and Drucker–Prager yield surfaces. The distinct irreversible processes are described in terms of two internal variables: an internal hardening variable, associated with accumulated compressive (plastic) strains, and an internal softening variable, linked with accumulated (plastic) shear strains. Motivated by both numerical and physical reasons, a parabolic plastic potential function is introduced to characterize the plastic flow on the linear Drucker–Prager failure surface. A thermodynamically consistent calibration procedure is employed to relate the softening modulus to fracture energy values obtained experimentally on Distaloy AE powder specimens. The predictive capability of the constitutive model is checked by simulating three representative cases: a diametral compression test, the ejection of an over-densified thin cylindrical part and the compaction of an axially symmetric multilevel part in an advanced CNC press machine. These simulations demonstrate the ability of the model to detect evidence of macroscopic cracks, clarify and provide reasons for the formation of such cracks, and evaluate, at least qualitatively, the influence of variations in the input variables on their propagation through the green compact

  Abstract
  This paper presents a constitutive model describing the mechanical behavior of metal powders during (uniaxial) cold die compaction processes, placing special emphasis on the [...]

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• A 3D Frictionless Contact Domain Method for Large Deformation Problems

  S. Hartmann, R. Weyler, J. Oliver, J. Hernández

  CMES: computer modeling in engineering and sciences (2010). Vol. 55 (3), pp. 211-269

  
  

  Abstract

  This work describes a three-dimensional contact domain method for large deformation frictionless contact problems. Theoretical basis and numerical aspects of this specific contact method are given in [Oliver, Hartmann, Cante, Weyler and Hernández (2009)] and [Hartmann, Oliver, Weyler, Cante and Hernández (2009)] for two-dimensional, large deformation frictional contact problems. In this method, in contrast to many other contact formulations, the necessary contact constraints are formulated on a so-called contact domain, which can be interpreted as a fictive intermediate region connecting the potential contact surfaces of the deformable bodies. This contact domain has the same dimension as the contacting bodies. It will be endowed with a displacement field, interpolated from the displacements at the contact surfaces and will be subdivided into a non-overlapping set of contact patches, where the contact constraints will be applied. For the enforcement of these contact constraints a stabilized Lagrange multiplier method is used, which allows the condensation of the introduced Lagrange multipliers, leading to a purely displacement driven problem.

  Abstract
  This work describes a three-dimensional contact domain method for large deformation frictionless contact problems. Theoretical basis and numerical aspects of this specific [...]

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• On the numerical resolution of the discontinuous material bifurcation problem

  J. Oliver, A. Huespe, J. Cante, G. Díaz

  International Journal for Numerical Methods in Engineering (2010). Vol. 83, pp. 768-804

  
  

  Abstract

  The work focuses on the numerical resolution of the discontinuous material bifurcation problem as a relevant ingredient in computational material failure mechanics. The problem consists of finding the conditions for the strain localization onset in terms of the so-called bifurcation time, localization directions and localization modes. A numerical algorithm, based on the iterative resolution of a coupled eigenvalue problem in terms of the localization tensor, is proposed for such purpose. The algorithm is shown to be always convergent to the exact solution for the symmetric case (major and minor symmetries of the tangent constitutive operator). In the unsymmetric case (only minor symmetries), the solution is no longer exact, although it is shown that using the symmetric part of the localization tensor in the proposed algorithms provides enough accurate solutions for most of cases. Numerical examples illustrate the benefits of the proposed methodology in terms of accuracy and savings in the computational cost associated with the problem.

  Abstract
  The work focuses on the numerical resolution of the discontinuous material bifurcation problem as a relevant ingredient in computational material failure mechanics. The problem [...]

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• A contact domain method for large deformation frictional contact problems. Part 2: Numerical aspects

  S. Hartmann, J. Oliver, R. Weyler, J. Cante, J. Hernández

  Computer Methods in Applied Mechanics and Engineering (2009). Vol. 198 (33-36), pp. 2607-2631

  
  

  Abstract

  This second part of the work describes the numerical aspects of the developed contact domain method for large deformation frictional contact problems. The theoretical basis of this contact method is detailed in the first part of this work. Starting from this, the present contribution focuses on describing important algorithmic details that go along with the finite element implementation for two-dimensional problems. Important aspects are the construction of the contact domain mesh, via a constraint Delaunay triangulation, the linearization of the discretized contact contributions and some important technical aspects about the extrapolation procedure used for the predictive active set strategy. Finally a set of numerical examples is presented to demonstrate the performance of the developed contact strategy. Demanding static and dynamic contact problems in the context of large deformations, including frictional effects as well as self contact, show the wide applicability and the robustness of the proposed method

  Abstract
  This second part of the work describes the numerical aspects of the developed contact domain method for large deformation frictional contact problems. The theoretical basis [...]

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