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Research areas within the automotive industry are dedicated to reducing the weight and emissions of vehicles. Through the application of lightweight materials, such as polymers, fuel consumption and production costs can be decreased. Therefore, understanding the mechanical responses and failure mechanisms of these materials is significant to the development and design of vehicular structural components. Experimental tests were performed to capture the time, temperature, and stress state dependence, as well as failure mechanisms and large-strain mechanical responses of polypropylene (PP) and copolymer polypropylene (co-PP). Alongside studying the mechanical responses of PP and co-PP, the deformation mechanisms associated with the ductile and brittle failures were also examined. By applying an Internal State Variable (ISV) model, the mechanical behavior of PP and co-PP under various strain rates and temperatures was predicted. Phenomenological, mechanics based failure criteria were also applied to the model to predict the ductile or brittle failure of the materials.

Modern engineering analysis requires accurate, reliable and efficient evaluation of outputs of interest. These outputs are functions of "input" parameter that serve to describe a particular configuration of the system, typical input geometry, material properties, or boundary conditions and loads. In many cases, the input-output relationship is a functional of the field variable - which is the solution to an input-parametrized partial differential equations (PDE). The reduced-basis approximation, adopting off-line/on-line computational procedures, allows us to compute accurate and reliable functional outputs of PDEs with rigorous error estimations. The operation count for the on-line stage depends only on a small number N and the parametric complexity of the problem, which make the reduced-basis approximation especially suitable for complex analysis such as optimizations and designs. In this work we focus on the development of finite-element and reduced-basis methodology for the accurate, fast, and reliable prediction of the stress intensity factors or strain-energy release rate of a mode-I linear elastic fracture problem. With the use of off-line/on-line computational strategy, the stress intensity factor for a particular problem can be obtained in miliseconds. The method opens a new promising prospect: not only are the numerical results obtained only in miliseconds with great savings in computational time; the results are also reliable - thanks to the rigorous and sharp a posteriori error bounds. The practical uses of our prediction are presented through several example problems. / Singapore-MIT Alliance (SMA)

A novel, general, numerical model is described that is capable of predicting the load-displacement relationship up to and at failure of multiple-bolt joints in timber of various configurations. The model is not tied to a single input function and bolt holes are permitted to be drilled oversize resulting in a slack system. The model consists of five parts. A new mathematical hysteresis model describes the stiffness of the individual bolt at each time step increment and accounts for non-linear and slack behavior; a mechanically-based structural stiffness model explains the interaction of one bolt with another bolt within a joint; an analytically-based failure model computes the stresses at each time step and initiates failure if crack length equals fastener spacing; a stochastic routine accounts for material property variation; and a heuristic optimization routine estimates the parameters needed. The core model is a modified array of differential equations whose solution describes accurate hysteresis shapes for slack systems. Hysteresis parameter identification is carried out by a genetic algorithm routine that searches for the best-fit parameters following evolutionary principles (survival of the fittest). The structural model is a linear spring model. Failure is predicted based on a newly developed 'Displaced-Volume-Method' in conjunction with beam on elastic foundation theory, elastic theory, and a modified Tsai-Wu Failure criterion. The devised computer model enhances the understanding of the mechanics of multiple-bolt joints in timber, and yields valid predictions of joint response of two-member multiple-bolt joints. This research represents a significant step towards the simulation of structural wood components. / Ph. D.

Student Number: 0420801P Master of Science in Engineering. Faculty of Engineering and the Built Environment / Underground observations at a coal mine indicated failure of the immediate roof above the bords while pillars were observed to be intact. To determine the underlying causes of roof failures, careful observations and photographic recording of occurrences of roof failures have been made. Rock samples of the immediate shale roof were collected for laboratory testing to determine the rock strength and deformation properties. Numerical simulations were carried out to analyse stress and strain distributions and also to attempt to explain the guttering process. Mapping of roof failures showed that these took place mainly towards the centre of the roadways. The roof failures, termed “roof guttering”, were observed to occur violently and with little warning. Occurrence of roof guttering had a negative impact on production. Some panels are abandoned, production times have increased and safety of workers is compromised. The mine authorities initially thought that roof guttering was caused by shear failure of the rock mass. Roof bolts are therefore used as a means of primary support. No improvements have been observed. Increasing the size of pillars has not solved the problem either. It has only increased the amount of coal left in the pillars without any improvements in reducing roof failures. Stress measurement results carried out in 2001 showed that high horizontal stresses exist at the mine. The immediate shale roof was observed to be weak. Laboratory testing showed that the shale rock is transversely isotropic. Numerical modelling results indicated that there are insignificant stress concentrations towards the centre of the roadway using the elastic and transversely isotropic elastic models. Stress concentrations were predicted at the roof-pillar contact area. It is therefore expected that failure should initiate and occur at the roof-pillar contact area. The Mohr-Coulomb and Mohr-Coulomb strain softening models predicted shear failure at the roof-pillar contact area. The two models over predicted the depth and under predicted the width of failures. The extension strain criterion predicted correctly the depth and width of failures although the failures were predicted at the roof-pillar contact area while the observations indicated failure mainly towards the centre of the roads. Initiation of failure was predicted ahead of the coal face at the centre of the road position using the extension strain criterion. Although none of the constitutive behaviours predicted correctly the observed underground failures the extension strain criterion has shown the best agreement. Guttering that occurred at the roof-pillar contact was modelled successfully using the extension strain criterion. The extension strain criterion predicted initiation of failure ahead of the coal face at the road centre position. It is possible that fracture initiation could be taking place in this location ahead of the coal face, and, on blasting the rock that has been fractured falls forming a gutter at the centre of the road.

Les aciers ODS (Oxide Dispersion Strengthened) sont envisagés comme matériau de gainage du combustible pour les futurs réacteurs nucléaires au sodium de Génération IV. Ces matériaux présentent une excellente résistance au fluage à haute température et au gonflement sous irradiation, mais des interrogations subsistent quant à leur propriété de résilience. L'objectif de ce travail de thèse est alors de comprendre l'effet de différents paramètres (composition chimique, texture, vieillissement thermique…) sur le comportement à l'impact des aciers ODS et sur l'apparition de la rupture de type fragile. L'objectif à terme est d'appréhender l'apparition de ce type de rupture afin d'assurer l'intégrité des composants en acier ODS en conditions normales ou incidentelles.Dans un premier temps, cette étude a permis d'évaluer la stabilité de deux nuances d'acier ODS contenant 14%Cr et 18%Cr dans des conditions de vieillissement thermique. La nuance à 18%Cr a été écartée à cause de la formation d'une phase intermétallique fragilisante de type sigma à 600°C. Par contre, la nuance à 14%Cr est plus prometteuse puisque son comportement est resté stable entre 400°C et 600°C pour une durée de vieillissement maximale de 10000 heures, et ce même si des précipités de phases alpha', de Laves Fe2W et des carbures de chrome ont été observés. D'autre part, la texture morphologique, caractérisée par des grains allongés selon la direction de filage, est propice à la propagation de fissures intergranulaires selon cette direction. La texture cristallographique régit, quant-à elle, les micromécanismes de clivage. En effet, les entités microstructurales qui contrôlent la propagation du clivage sont des groupes de grains faiblement désorientés les uns des autres d'un point de vue cristallographique, et qui sont associés à la notion de grains effectifs. Enfin, le comportement en traction et en flexion d'une nuance d'acier ODS à 14%Cr a été modélisé, et un critère de rupture fragile basé sur une valeur de contrainte critique a été proposé. Ce modèle nous a alors permis de simuler des essais sur différentes géométries et de prédire l'apparition de la rupture fragile sur cette nuance. / The Oxide Dispersion Strengthened (ODS) steels have been identified as potential materials for fuel cladding in Generation IV nuclear reactors. They are characterized by a very good resistance to swelling under irradiation and to high temperature creep, but questions still remain about the impact toughness of these materials. The first aim of this work is to understand the effects of different parameters (chemical composition, texture, thermal ageing...) on the impact behaviour of ODS steels. The final objective is to predict the occurrence of the brittle failure on the ODS steel components in normal or incidental conditions.Firstly, this study assesses the stability of two ODS steel grades containing either 14%C or 18%Cr during thermal ageing. The 18%Cr steel grade has been discarded due to the growing of the brittle intermetallic sigma phase at 600°C. However, the 14%Cr steel grade showed a promising behaviour given the stability of its mechanical properties after thermal ageing between 400°C and 600°C, for a maximum duration of 10000 hours, and regardless of the presence of chromium carbides, alpha' and Laves phases. Then, the morphological texture characterized by elongated grains along the extrusion direction enhances the propagation of intergranular cracks along this direction. Meanwhile, the crystallographic texture controls the cleavage micromechanisms. Indeed, the microstructural entities that control the propagation of the cleavage crack are groups of grains which are characterized by low crystallographic misorientations and referred to as effective grains. At last, the tensile and bending behaviour of a 14%Cr ODS steel grade has been modelled. A brittle failure criterion based on a critical stress value had also been suggested. This model allowed us to simulate mechanical tests on different geometries and to predict the occurrence of the brittle failure.

Nous proposons une nouvelle approche inspirée des modèles d'endommagement non-locaux pour décrire la ruine des matériaux quasi-fragiles désordonnés. Les hétérogénéités matériaux sont introduites à une échelle continue mésoscopique via des variations spatiales de la résistance à l'endommagement alors que le mécanisme de redistribution des contraintes est décrit à travers une fonction d'interaction que l'on peut faire varier. L'évolution spatio-temporelle de l'endommagement est déterminée à partir du principe de conservation d'énergie et caractérisée via une étude statistique des précurseurs à la rupture. Cette approche nous permet de prédire la valeur des seuils de localisation et de rupture en fonction de la nature des redistributions. A l'approche de la rupture, nous mettons également en évidence une augmentation en loi de puissance du taux d'énergie dissipée ainsi qu'une longueur de corrélation, supportant l'interprétation de la rupture quasi-fragile comme un phénomène critique. En effet, nous démontrons que notre model d'endommagement s'apparente à la loi d'évolution d'une interface élastique évoluant dans un milieu désordonné. Cette analogie nous permet d'identifier les paramètres d'ordre et de contrôle de cette transition critique et d'expliquer les invariances d'échelle des fluctuations dans la limite champ moyen. Enfin, nous appliquons ces concepts théoriques à travers l'étude expérimentale de la compression d'un empilement bidimensionnel de cylindres élastiques. Notre approche permet de décrire de façon quantitative la réponse mécanique non-linéaire du matériau, et en particulier la statistique des précurseurs ainsi que la localisation des déformations. / We propose a novel approach inspired from non-local damage continuum mechanics to describe damage evolution and quasi-brittle failure of disordered solids. Heterogeneities are introduced at a mesoscopic continuous scale through spatial variations of the material resistance to damage. The central role played by the load redistribution during damage growth is analyzed by varying the interaction function used in the non-local model formulation. The spatio-temporal evolution of the damage field is obtained from energy conservation arguments, so that the formulation is thermodynamically consistent. We analytically determine the onsets of localization and failure that appear controlled by the redistribution function. Damage spreading is characterized through a complete statistical analysis of the spatio-temporal organization of the precursors to failure. The power law increase of the rate of energy dissipated by damage and an extracted correlation length close to failure supports the interpretation of quasi-brittle failure as a critical phenomena. Indeed, we establish a connection between our damage model and the evolution law of an elastic interface driven in a disordered medium. It allows to identify the order and control parameters of the critical transition, and capture the scale-free statistical properties of the precursors within the mean field limit. Finally, we experimentally investigate the coaction of localized dissipative events and elastic redistributions in disordered media via compression experiments of two-dimensional arrays of hollow soft cylinders. Our experimental observations show a quantitative agreement with the predictions derived following our approach.

Ce travail vise à améliorer la compréhension et la modélisation de la rupture des matériaux métalliques à gradient de propriétés. L'application se fait sur des pignons en acier 20MnB5 carbonitrurés insérés dans un "recliner", mécanisme de sécurité des siègesautomobiles. Le traitement de carbonitruration consisteà enrichir en carbone et azote une couche externe despièces en les chauffant dans le domaine austénitiquedans une atmosphère riche en ces deux éléments. Puisles pièces sont trempées afin de déclencher unetransformation martensitique. On obtient ainsi unmatériau à gradient de propriétés, intéressant pour despièces de transmission de puissance comme lesengrenages. Ce projet a commencé par l’analyse de larupture de mécanismes de sièges en test industriel. Celaa confirmé le double comportement à rupture binaire dumatériau : fragile sur une couche externe, ductile àl’intérieur. Un banc d’essai, spécialement conçu pour ceprojet, soumet une dent à un effort latéral jusqu’àrupture complète. Des observations in situ sonteffectuées et la courbe force-déplacement estenregistrée, montrant la diversité de comportement enfonction de la profondeur d'engagement des dents et dela présence ou non de la couche carbonitrurée. Desessais de traction, de flexion 4 points et de cisaillementsur éprouvettes papillons sont utilisés pour mesurer lespropriétés plastiques et calibrer les critères de rupturede la couche carbonitrurée comme de l'acier de base. Laplasticité de Von Mises avec une loi d'écrouissagesimple rend très bien compte de tous ces essaismécaniques. Différents critères de rupture ductile issusde la littérature sont calibrés; ils ne parviennent pas àreprésenter correctement tous les essais réalisés.Un critère plus adapté est donc proposé enconclusion de cette campagne expérimentale. Lasimulation de la rupture dans LS-Dyna est réaliséeavec une technique d'érosion d'éléments dont leslimitations sont discutées. La comparaison avec larupture de dent expérimentale permet d'évaluer lescritères numériques identifiés et d'analyser leslimites actuelles de la simulation, en particulier lanécessité de prendre en compte plus finement àl'avenir le gradient de propriétés mécaniques ainsique les contraintes résiduelles de compression dela couche carbonitrurée. / This work aims at a better understanding and modeling of the failure of gradient metallic materials. It is applied to carbonitrided pinions made out of 20MnB5 steel, inserted in a "recliner", a safety mechanism of automotive seats. Carbonitriding induces high surface hardness while preserving significant core ductility. The experimental analysis of the fracture behavior of seat recliners in an industrial test confirmed the dual failure behavior of the component : brittle external layer, ductile core material. A test bench has been specifically designed for the project: one tooth is submitted to a lateral force until complete failure. In situ observations are performed and the load-displacement curve recorded, showing a variety of behaviors as a function of the teeth engagement depth and of the presence or not of the carbonitrided layer. Experimental tests with various tress states were conducted to measure plastic properties as well as to calibrate fracture criteria, for the carbonitrided layer and for the core steel. Von Mises plasticity and a simple strain hardening curve fit very well all these experiments. As fracture criteria from the literature were unable to predict failure correctly for all the mechanical tests, an adapted criterion has therefore been proposed as an outcome of this extensive mechanical testing campaign. Fracture simulation in LS Dyna has been performed using the element erosion technique, the limitations of which are discussed. Comparison with the experimental tooth fracture measurements allows evaluation of the proposed failure criteria, and enables to stress out and discuss the present limits of the simulation, concluding that it will be necessary in future work to account more finely for the mechanical property gradient together with the compressive residual stresses in the carbonitrided layer.

Clay shales are currently being assessed as possible host rock formations for the deep geological disposal of radioactive waste. However, one main concern is that the favourable long-term isolation properties of the intact rock mass could be negatively affected by the formation of an excavation damaged zone (EDZ) around the underground openings. This thesis investigated the deformation and failure process of a clay shale, namely Opalinus Clay, with particular focus on the influence of anisotropy on the short-term response of circular tunnels. To achieve this goal, a hybrid continuum-discontinuum numerical approach was used in combination with new field measurements from the Mont Terri underground research laboratory. The response of Opalinus Clay during the excavation of a full-scale emplacement (FE) test tunnel was characterized by geodetic monitoring of wall displacements, radial extensometers and longitudinal inclinometers. The deformation measurements indicated strong directionality induced by the combined effect of in situ stress field and presence of bedding planes striking parallel to the tunnel axis, with the most severe deformation occurring in the direction approximately perpendicular to the material layering. Computer simulations were conducted using a newly-extended combined finite-discrete element method (FEM/DEM), a numerical technique which allows the explicit simulation of brittle fracturing and associated seismicity. The numerical experimentation firstly focused on the laboratory-scale analysis of failure processes (e.g., acoustic activity) in brittle rocks, and on the role of strength and modulus anisotropy in the failure behaviour of Opalinus Clay in tension and compression. The fracturing behaviour of unsupported circular excavations in laminated rock masses was then analyzed under different in situ stress conditions. Lastly, the modelling methodology was applied to the aforementioned FE tunnel to obtain original insights into the possible EDZ formation process around emplacement tunnels for nuclear waste. The calibrated numerical model suggested delamination along bedding planes and subsequent extensional fracturing as key mechanisms of the damage process potentially leading to buckling and spalling phenomena. Overall, the research findings may have a potential impact on the constructability and support design of an underground repository as well as implications for its long-term safety assessment procedure.

Clay shales are currently being assessed as possible host rock formations for the deep geological disposal of radioactive waste. However, one main concern is that the favourable long-term isolation properties of the intact rock mass could be negatively affected by the formation of an excavation damaged zone (EDZ) around the underground openings. This thesis investigated the deformation and failure process of a clay shale, namely Opalinus Clay, with particular focus on the influence of anisotropy on the short-term response of circular tunnels. To achieve this goal, a hybrid continuum-discontinuum numerical approach was used in combination with new field measurements from the Mont Terri underground research laboratory. The response of Opalinus Clay during the excavation of a full-scale emplacement (FE) test tunnel was characterized by geodetic monitoring of wall displacements, radial extensometers and longitudinal inclinometers. The deformation measurements indicated strong directionality induced by the combined effect of in situ stress field and presence of bedding planes striking parallel to the tunnel axis, with the most severe deformation occurring in the direction approximately perpendicular to the material layering. Computer simulations were conducted using a newly-extended combined finite-discrete element method (FEM/DEM), a numerical technique which allows the explicit simulation of brittle fracturing and associated seismicity. The numerical experimentation firstly focused on the laboratory-scale analysis of failure processes (e.g., acoustic activity) in brittle rocks, and on the role of strength and modulus anisotropy in the failure behaviour of Opalinus Clay in tension and compression. The fracturing behaviour of unsupported circular excavations in laminated rock masses was then analyzed under different in situ stress conditions. Lastly, the modelling methodology was applied to the aforementioned FE tunnel to obtain original insights into the possible EDZ formation process around emplacement tunnels for nuclear waste. The calibrated numerical model suggested delamination along bedding planes and subsequent extensional fracturing as key mechanisms of the damage process potentially leading to buckling and spalling phenomena. Overall, the research findings may have a potential impact on the constructability and support design of an underground repository as well as implications for its long-term safety assessment procedure.