La fabrication de matériaux ductiles insère généralement des impuretés dans leurs compositions microscopiques. Ces impuretés peuvent se détacher de la matrice environnante et même se fissurer lors d’une déformation progressive. En raison de la résultante incapacité de ces particules indésirables à supporter toute contrainte, ces matériaux ductiles sont, de manière équivalente, supposés être poreux. Il a été largement démontré que la porosité joue un rôle fondamental dans les mécanismes de la rupture ductile. Depuis les années 1970, de nombreux modèles micromécaniques ont été proposés dans le but de décriremathématiquement ces mécanismes. Parmi eux, le célèbre modèle de Gurson combine la technique d’homogénéisation avec le théorème cinématique de l’analyse limite pour estimer le critère de plastification macroscopique et la loi d’évolution de la porosité des matériaux ductiles poreux. Cependant, le modèle de Gurson, ainsi que la plupart de ses extensions, ne tient compte que de la rupture ductile isotrope. Le but du présent travail est donc de contribuer à la conception de critères de plastification pour la rupture ductile des milieuxporeux anisotropes. Trois contributions principales tirant parti d’hypothèses similaires à celles du modèle de Gurson sont ici proposées. La première contribution est l’évaluation de l’influence de la morphologie des vides sur les critères de plastification macroscopique de ces classes de matériaux. La deuxième est l’inclusion d’un critère de plastification anisotrope dans la matrice du matériau, de sorte que le comportement macroscopique présente une anisotropie induite par cette matrice, y compris pour les cavités sphériques. Le troisième et dernier progrès consiste à généraliser le critère de plastification de la matrice afin d’inclure une classe de fonctions de plastification basée sur des transformations linéaires. Cette classe de fonction a été largement employée avec succès pour représenter des alliages d’aluminium à haute résistance. Les résultats ici présentés soulignent la cohérence et la robustesse des trois formulations. En outre, le rôle de la porosité sur la modélisation de la plasticité des alliages d’aluminium incite à poursuivre les travaux sur la caractérisation expérimentale des paramètres d’anisotropie. / The manufacturing of ductile materials generally inserts impurities into their microscopic composition. These impurities may detach from the surrounding matrix and even crack along progressive deformation. Due to the consequent incapacity of these undesirable particles of supporting any stress, these ductile materials are equivalently assumed to be porous. Porosity has been effectively shown to play a fundamental role in the mechanisms of ductile fracture. Many micromechanical models have been proposed since the 1970s with the aim of mathematically describing these mechanisms. Among them, the acclaimed Gursonmodel combines the averaging homogenization technique with the kinematic theorem of Limit Analysis to estimate the macroscopic yield criterion and porosity evolution law of porous ductile materials. However, the Gurson model and most of its extensions only account for isotropic ductile fracture. Thus, the purpose of the present work is to contribute to the conception of yield criteria for anisotropic porous ductile rupture. Three main contributions are hereby proposed by profiting from similar hypothesis to those of the Gurson model. The first contribution is the assessment of the influence of void morphology on overall yield criteria for those classes of materials. The second is the inclusion of ananisotropic yield criterion in the material matrix so that the macroscopic behavior present matrix-induced anisotropy even for spherical cavities. The third and last advancement consists of generalizing the material matrix yield criterion of the Gurson model in order to comprehend a linear transformation-based class of yield functions that has been widely used to represent specific high strength aluminum alloys. The results hereby presented highlight the consistency and robustness of the three formulations. Moreover, the role of the porosity on the modeling of yield behavior of aluminum alloys encourages further work regarding experimental parameter characterization.

Plane strain transient finite thermomechanical deformations of heat-conducting particulate composites comprised of circular tungsten particulates in nickel-iron matrix are analyzed using the finite element method to delineate the initiation and propagation of brittle/ductile failures by the nodal release technique. Each constituent and composites are modeled as strain hardening, strain-rate-hardening and thermally softening microporous materials. Values of material parameters of composites are derived by analyzing deformations of a representative volume element whose minimum dimensions are determined through numerical experiments. These values are found to be independent of sizes and random distributions of particulates, and are close to those obtained from either the rule of mixtures or micromechanics models. Brittle and ductile failures of composites are first studied by homogenizing their material properties; subsequently their ductile failure is analyzed by considering the microstructure. It is found that the continuously varying volume fraction of tungsten particulates strongly influences when and where adiabatic shear bands (ASB) initiate and their paths. Furthermore, an ASB initiates sooner in the composite than in either one of its constituents. We have studied the initiation and propagation of a brittle crack in a precracked plate deformed in plane strain tension, and a ductile crack in an infinitely long thin plate with a rather strong defect at its center and deformed in shear. The crack may propagate from the tungsten-rich region to nickel-iron-rich region or vice-a-versa. It is found that at the nominal strain-rate of 2000/s the brittle crack speed approaches Rayleigh's wave speed in the tungsten-plate, the nickel-iron-plate shatters after a small extension of the crack, and the composite plate does not shatter; the minimum nominal strain-rate for the nickel-iron-plate to shatter is 1130/s. The ductile crack speed from tungsten-rich to tungsten-poor regions is nearly one-tenth of that in the two homogeneous plates. The maximum speed of a ductile crack in tungsten and nickel-iron is found to be about 1.5 km/s. Meso and multiscale analyses have revealed that microstructural details strongly influence when and where ASBs initiate and their paths. ASB initiation criteria for particulate composites and their homogenized counterparts are different. / Ph. D.

The presented work is concerning with ductile fracture problematic under monotonic loading which is result of gradual material degradation at large plastic deformation. At present, a large number of models, which calibration is not trivial, are used for its prediction. Ductile fracture mechanisms and cut-off region are described in the literature search part. Next, there is given a summary of criteria which are based on different approaches to ductile fracture. There were proposed and used KHPS and KHPS2 criteria within this PhD thesis. Procedure of assessment of the stress-strain curve and ductile fracture criteria calibration are described in last part of the literature search. A summary of tests, which were done in order to calibrate chosen criteria, is given in experimental part. Various stress states within broad range of stress triaxiality and Lode parameter were reached using these tests. Special type of specimen, by which very low stress triaxiality value is reached, was designed within this work. All specimens were made from the steel 12 050. Wrought rods of one melt with circular cross-section of 27 mm in diameter were used as semi-product. Calibration of chosen ductile fracture criteria was performed using foregoing tests. These criteria were implemented by author into explicit finite element software ABAQUS/Explicit using user subroutine VUMAT. Chosen criteria were used for simulation of multistep extrusion at which formation of internal central cracks occurs. These criteria were also used for simulation of cutting of circular cross-section rods. Results from simulation were compared to experiments which were done by industrial partner J-VST.

L'objectif de cette thèse de doctorat est de contribuer à une meilleure compréhension et modélisation de la rupture ductile lors de la mise en forme des métaux. Cette mise en forme se réalise en général par une série de chargements thermomécaniques où de multiples paramètres comme le type et la direction de chargement varient. Des outils de simulations prédictifs sont nécessaires pour modéliser les mécanismes de rupture, et ensuite optimiser les coûts de production.La rupture ductile des matériaux métalliques est précédée par la détérioration progressive de leur capacité de charge due à la germination, croissance, et coalescence de cavités microscopiques. Dans ce travail, une approche micromécanique est développée afin de conduire des simulations éléments finis réalistes et à champ complet de la rupture ductile à l'échelle microscopique. Des méthodes de génération et d'adaptation de maillage s'appuyant sur des fonctions de niveau sont proposées pour discrétiser la microstructure. Avec ces méthodes, les propriétés géométriques des fonctions de niveau sont conservées, ainsi que le volume et la morphologie de chaque composante de la microstructure, et ce pour de grandes déformations plastiques. Ces méthodes numériques sont étendues pour permettre la modélisation de fissures aux interfaces entre certaines composantes de la microstructure, ou à l'intérieur même de ces composantes. Une nouvelle méthode de détection de contact par adaptation de maillage est aussi développée.L'intérêt de ces développements numériques et modèles micromécaniques est démontré tout d'abord pour des microstructures générées statistiquement. Ensuite, une nouvelle méthodologie est proposée pour modéliser des microstructures réelles (laminographie in-situ) avec des conditions aux limites mesurées expérimentalement (corrélation d'images volumiques). / The present PhD thesis aims at a better understanding and modeling of ductile fracture during the forming of metallic materials. These materials are typically formed using series of thermomechanical loads where many parameters such as loading type and direction vary. Predictive numerical tools are necessary to model fracture mechanisms, and then optimize production costs.Ductile fracture in metallic materials is the result of a progressive deterioration of their load carrying capacity due to the nucleation, growth, and coalescence of microscopic voids. In this work, a micromechanical approach is developed in order to conduct realistic full field finite element simulations of ductile fracture at the microscale. Meshing and remeshing methods relying on the use of Level-Set functions are proposed to discretize the microstructure. Thanks to these methods, the geometric properties of Level-Set functions are preserved, as well as the volume and morphology of each component of the microstructure, even at large plastic strains. These numerical methods are extended to account for cracks and model the failure of some components of the microstructure, or interfaces between them. A new contact detection method based on mesh adaptation is also developed.The interest of these numerical developments and micromechanical models is first demonstrated at the scale of representative volume elements with statistically generated microstructures. Then, a new methodology is proposed to conduct simulations of real microstructures observed via in-situ X-ray laminography, with boundary conditions that are measured using digital volume correlation techniques.

O presente trabalho visa o estudo e avaliação de diversos modelos de falha através de ensaios experimentais e análises numéricas. A caracterização do material foi feita por meio de ensaios de tração de espécimes com e sem entalhe e de cisalhamento, para prover dados em uma ampla faixa de triaxialidade. A calibração dos parâmetros necessários para cada modelo de falha ocorreu através da obtenção das componentes de tensões e de deformações na região de ruptura, obtidas por meio de análises numéricas destes ensaios. O critério da máxima deformação plástica equivalente, modelo de dano de Johnson-Cook e critério da máxima tensão cisalhante foram aplicados em um caso de impacto em pára-choque. Diversos ensaios de impacto foram realizados até a que se atingisse a ruptura satisfatória do componente. Os ensaios foram modelados em elementos finitos, através do programa comercial LS-Dyna®, sendo que os modelos de falha calibrados foram aplicados para o ensaio onde se ocorreu ruptura. Houve boa concordância entre os resultados obtidos numericamente e experimentalmente, respeitadas as observações realizadas acerca da especificidade deste caso de impacto em baixa velocidade. / The aim of the present work is an assessment of several fracture models through experiments and numerical simulations. Tensile tests with notched and unnotched specimens were carried out to provide the material characterization in a wide range of stress triaxiality. The calibration of the parameters required by the fracture models was enabled by the parallel numerical simulation of the tensile tests, providing information on the stress and strain components at the failure locus. The constant equivalent strain criterion, the Johnson-Cook failure model and the maximum shear stress failure criterion were applied in a bumper beam impact case study. Several low speed impact tests were carried out in order to result in the components rupture. Numerical simulation of the experiments was performed using commercial finite element code LS-Dyna®. Good correlation of experiments and numerical simulations was achieved when considering this particular low speed case study.

Este trabalho apresenta o desenvolvimento de procedimentos para a medição de curvas de resistência J-R em espécimes SE(T) usando os métodos de flexibilidade elástica e método n. Uma descrição da metodologia sobre a qual J e o crescimento de trinca são medidos estabelece o contexto para determinar dados de resistência ao rasgamento dúctil com o emprego de curvas carga vs. deslocamento obtidas experimentalmente. A extensiva matriz de análises em estado plano de deformações de espécimes SE(T) complementada, em algumas geometrias selecionadas, com análises 3D permite a determinação numérica da flexibilidade adimensional, u, e fatores nJ e Y para uma grande faixa de proporções geométricas e propriedades de material características de aços estruturais e para dutos. Ensaios laboratoriais de um aço API 5L X60 à temperatura ambiente usando espécimes SE(T) carregados por pinos com entalhes laterais (side-grooves) fornecem os dados de carga e deslocamento necessários para validar o procedimento para determinar curvas de resistência do material. Os resultados apresentados nesta tese fornecem uma base de soluções para o futuro estabelecimento de norma padronizada para a medição experimental de curvas J-R em corpos de prova SE(T) mecanicamente similares a dutos com defeitos bidimensionais. / This work provides an estimation procedure to determine J-resistance curves for pinloaded and clamped SE(T) fracture specimens using the unloading compliance technique and the n-method. A summary of the methodology upon which J and crack extension are derived sets the necessary framework to determine crack resistance data from the measured load vs. displacement curves. The extensive plane-strain analyses and key 3D results enable numerical estimates of the nondimensional compliance, u , and parameters n and Y for a wide range of specimen geometries and material properties characteristic of structural and pipeline steels. Laboratory testings of an API 5L X60 steel at room temperature using pin-loaded SE(T) specimens with side-grooves provide the load-displacement data needed to validate the estimation procedure for measuring the crack growth resistance curve for the material. The results presented in the this thesis produce a representative set of solutions which lend further support to develop standard test procedures for constraint-designed SE(T) specimens applicable in measurements of crack growth resistance for pipelines.

Pour les gazoducs, la résistance à la propagation ductile est reliée à la fraction surfacique de “shear area” mesurée dans l’essai Drop Weight Tear Test (DWTT). Récemment, un mode de rupture “inverse” a parfois été observé sur les éprouvettes DWTT dans cas d’aciers ayant une énergie Charpy très élevée. Ceci est un problème car la résistance à la propagation fragile est alors sous-estimée dans la cas d’aciers à haute ténacité. Une procédure pour évaluer l’effet de la rupture inverse manque encore. De plus, le mécanisme conduisant à la rupture inverse n’a pas été expliqué en détail. Il est donc important de développer des modèles de simulations permettant d’interpréter les essais DWTT présentant une rupture “inverse”. Cette étude vise à proposer un modèle de rupture pour l’essai DWTT représentant la rupture ductile en biseau ainsi que la rupture fragile. Cette étude comprend : (i) une modèle de plasticité anisotrope, (ii) une simulation de la rupture en biseau, (iii) un modèle de transition ductile—fragile. Bien décrire la plasticité est nécessaire pour bien estimer les contraintes et déformations dans la zone de fissuration. La rupture ductile est représentée avec un modèle GTN incluant un terme de germination dépendent du paramètre de Lode. La rupture fragile est étudiée avec le modèle de Beremin appliqué après simulation de la rupture ductile. A la lumière de cette simulation, il est possible de mieux comprendre l’essai DWTT. Ces résultats seront utiles pour promouvoir l’emploi des aciers à haute ténacité pour les gazoducs sous haute pression. / For the gas line-pipe, resistance to brittle fracture propagation is related to shear area fraction measured in Drop Weight Tear Test (DWTT). Recently, “so-called” inverse fracture is sometimes observed in DWTT specimens for line-pipe with high Charpy absorbed energy. The main problem of the inverse fracture is that the resistance to brittle fracture propagation is underestimated in case of high toughness steels. However, the rational guidelines to evaluate the effect of inverse fracture are still missing. Moreover, the mechanism of inverse fracture has not yet been clarified in details. It is important to establish the simulation models representing the DWTT fracture surface to clarify the mechanisms of inverse fracture. This study aims at the simulation model representing the slant ductile fracture and ductile to brittle transition during DWTT. The study includes the description of: (i) the anisotropic plastic behavior, (ii) slant ductile behavior and (iii) ductile to brittle transition behavior. The description of anisotropic plastic behavior is needed to be able to precisely estimate strains and stresses within the structures. The slant ductile fracture behavior is numerically investigated by using the GTN model with additional secondary void nucleation. The brittle fracture is studied by extending the Beremin model to brittle fracture initiation after slant ductile fracture. This study discusses the mechanism of inverse fracture during DWTT from these simulation results. This research results will be helpful to be able to use high toughness steels for natural gas line-pipes with high pressure transmission.

Le vieillissement dynamique se manifeste en particulier par le phénomène de Portevin-Le Chatelier (PLC). Il se produit dans les aciers aux environs de 200°C pour des sollicitations quasi-statiques. Dans les aciers au C-Mn, il conduit à une chute de ductilité et de ténacité qui doit être prise en compte dans le dimensionnement des structures de sûreté. L’objectif de la thèse consiste à modéliser le comportement mécanique des aciers au C-Mn en tenant compte du vieillissement dynamique et à prédire leur rupture ductile en présence de ce phénomène. Le comportement mécanique du matériau étudié, un acier au C-Mn, a été caractérisé par des essais de traction simple. Le modèle KEMC implémenté dans le code de calculs par éléments finis Zébulon, a été identifié sur ces essais : l’effet de Portevin Le-Chatelier (PLC) a été correctement simulé sur les éprouvettes lisses, entaillées et CT. Nous avons montré l’importance des conditions aux limites dans la manifestation du PLC. Pour la rupture ductile, l’application du critère de Rice et Tracey (identifié à 20°C) sur les éprouvettes entaillées AE4 montre que la prise en compte du vieillissement dynamique dans le comportement ne suffit pas pour avoir une bonne prédiction de la rupture. Des études micromécaniques de croissance de cavité indiquent que les localisations de PLC peuvent favoriser la croissance et la coalescence de cavité. L’écrouissage apparent, qui dépend du durcissement par la déformation mais aussi du durcissement provenant du vieillissement dynamique, modifie la vitesse de croissance de cavité, mais pas le taux critique de croissance de cavité. On identifie une loi d’endommagement dont les paramètres dépendent de la température à partir des calculs micromécaniques. Le nouveau modèle donne une meilleure prédiction que le modèle de Rice et Tracey sur les éprouvettes entaillées AE4 et a permis de prédire un creux de ténacité sur les éprouvettes CT. Pour améliorer les prédictions, la loi d’endommagement doit dépendre de la vitesse de déformation. / The dynamic strain aging is manifested especially by the Portevin-Le Chatelier (PLC) phenomenon. It appears in steels around 200°C at quasi static solicitation conditions. In C-Mn steels, it leads to a drop of ductility and of toughness which should be taken into account in the design of safety structures. The thesis aims to model the mechanical behavior of the C-Mn steels taking into account the dynamic strain aging and to predict the ductile fracture of these steels in the presence of the phenomenon. The mechanical behavior of the material studied, a C-Mn steel, was characterized using tensile tests. The KEMC model, which was implemented in the Finite Element program Zébulon, was identified using these tests: the Portevin-Le Chatelier (PLC) effect was correctly simulated on the tensile specimens, the notched specimens and the CT specimens. We showed the importance of boundary conditions in the occurrence of the PLC effect. As far as the ductile fracture is concerned, the application of the Rice and Tracey’s criterion (identified at 20°C) on the notched specimens AE4 showed that the consideration of the dynamic strain aging in the behavior was insufficient to give a good prediction of the fracture. Micromechanical studies of the growth of voids showed that PLC localizations can facilitate the growth and the coalescence of voids. The nominal strain hardening, which depends on the strain hardening and the hardening due to the dynamic strain aging, does not modify the critic growth ratio of voids but the growth rate of voids. We identified a damage model using micromechanical simulations. The parameters of this damage model depend on temperature. The new model gave a better prediction than the Rice and Tracey model on the notched specimens AE4 and it also allowed predicting the drop of toughness on the CT specimens. To improve the prediction of fracture, le damage law must depend on strain rate.