The mechanism of metal material failure due to inelastic cyclic deformations is commonly described as Low-Cycle Fatigue (LCF). Fracture in steel structures caused by earthquakes can be associated with this mechanism. Mathematical expressions describing the material deterioration due to LCF are often referred to as LCF laws. The accurate determination of the safety of steel structures against earthquake-induced failure requires the use of LCF laws which have been sufficiently validated with experimental test data. The present study combined experimental testing and computational simulation to enhance the understanding of structural steel fracture due to LCF. The experiments were conducted in specimens extracted from the flat and corner regions of two rectangular steel hollow sections with different thickness. A total of 60 cylindrical specimens with a circumferential notch were subjected to different combinations of axial and torsional loading. The loading protocols and notch geometry were designed to produce different stress states at the location of fracture initiation. Finite element analyses were conducted to obtain the stress state and inelastic strains at the fracture initiation location. This information was then used for the calibration of five existing LCF laws. The calibration also allowed the comparative evaluation of the capability of the different laws to capture fracture initiation for different stress states, with a single set of values for the various parameters. The accuracy of the calibrated LCF laws to predict fracture initiation in a large-scale test was also investigated. To this end, a test was conducted on a rectangular steel tube subjected to cyclic axial loading. A finite element analysis of this test was conducted, and predictions of the instant and location of fracture initiation using the calibrated LCF laws were compared with the experimental observations. / Doctor of Philosophy / The mechanism of material failure due to repeated cycles of large deformations is denoted as Low-Cycle Fatigue (LCF); this failure mechanism can occur in steel structures subjected to loading conditions such as those induced by earthquakes. Mathematical expressions that evaluate the material deterioration due to LCF are often used to predict the instant and location of fracture initiation in small-scale and large-scale tests. An experimental program was conducted for the study of fracture associated with LCF. A total of 60 specimens were fabricated with material extracted from the flat and corner regions of two rectangular steel tubes; the applied loads elongated and/or twisted the specimens until they ruptured. Computational simulations of these tests were conducted to obtain key information at the location of the observed fracture initiation. This information was used to adjust five mathematical expressions suggested by previous researchers that could predict the same instant of fracture initiation observed in the experiments. The accuracy of the predictions from each of these mathematical expressions was evaluated. The accuracy of these mathematical expressions to predict fracture initiation in a large-scale test was also investigated. To this end, an experiment was conducted on a rectangular steel tube subjected to repeated cycles of deformation. A computational simulation of this test was also developed, and predictions of the instant and location of fracture initiation were compared with the experimental observations.

This diploma thesis is an introduction to the ductile fracture under large plastic deformations and is focused to numerical simulation of this type of problems. Explicit finite element method (FEM) is discussed in theoretical introduction as the most powerful tool for numerical calculations in this area. Actual state of research and possibilities of ductile fracture simulations are presented. Applicable fracture criteria are collected in a summary sheet and the most important ones are selected and commented in detail. The problem of implementation of selected criteria into commercial FEM packages is discussed, too. Main part of the work is presented in chapters 7÷9 where two ductile fracture criteria (Equivalent Fracture Strain and Johnson-Cook) are applied to numerical simulation of material cutting. All results were obtained with ABAQUS/Explicit 6.5.1 and their verification was realized by experimental measurement.

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 Gurson model 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 an anisotropic yield criterion in the material matrix so that the macroscopic behavior presents 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 include 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. / A fabricação de materiais dúcteis insere impurezas em suas composições microscópicas. Essas impurezas podem se soltar da matriz circundante e até trincar durante um processo de deformação progressiva. Devido à consequente incapacidade destas partículas indesejáveis para suportar qualquer esforço, estes materiais dúcteis são equivalentemente assumidos como sendo porosos. Investigações experimentais têm extensamente mostrado que a porosidade desempenha um papel fundamental nos mecanismos de ruptura de materais dúcteis. Desde a década de 1970, vários modelos micromecânicos têm sido propostos para descrever esses mecanismos matematicamente. Entre eles, o célebre modelo de Gurson combina a técnica de homogeneização com o teorema cinemático da Análise Limite para estimar o critério de plastificação macroscópica e a lei de evolução da porosidade dos materiais dúcteis porosos. No entanto, o modelo de Gurson e a maioria de suas extensões consideram apenas situações de ruptura dúctil em meios isotrópos. O objetivo do presente trabalho é, portanto, contribuir para o desenvolvimento de critérios de plastificação para a ruptura dúctil de meios porosos anisotrópos. Três principais contribuições são propostas neste trabalho, as quais se valem de hipóteses semelhantes às do modelo de Gurson. A primeira contribuição é a avaliação da influência da morfologia do vazio nos critérios de plastificação macroscópica desta classe de materiais. A segunda é a inclusão de um critério de plastificação anisotrópico na representação da matriz do material, de modo que o comportamento macroscópico exiba anisotropia induzida por ela, mesmo para cavidades esféricas. O terceiro e último avanço é a generalização do critério de plasticidade da matriz de modo a incluir uma classe de funções de plastificação baseadas em transformações lineares. Esta classe de funcões tem sido amplamente utilizada com sucesso para modelar ligas de alumínio de alta resistência. Os resultados apresentados neste trabalho atestam a coerência e robustez das três formulações. Além disso, o papel da porosidade na modelagem da plasticidade das ligas de alumínio encoraja trabalhos futuros sobre a caracterização experimental de parâmetros de anisotropia.

The scaling of specific cutting energy is studied when micro-cutting ductile metals. A unified framework for understanding the scaling in specific cutting energy is first presented by viewing the cutting force as a combination of constant, increasing, and decreasing force components, the independent variable being the uncut chip thickness. Then, an attempt is made to isolate the constant force component by performing high rake angle orthogonal cutting experiments on OFHC Copper. The data shows a trend towards a constant cutting force component as the rake angle is increased. In order to understand the source of this constant force component the chip-root is investigated. By quickly stopping the spindle at low cutting speeds, the chip is frozen and the chip-workpiece interface is examined in a scanning electron microscope. Evidence of ductile tearing ahead of the cutting tool is seen at low and high rake angles. At higher cutting speeds a quick-stop device is used to obtain chip-roots. These experiments also clearly indicate evidence of ductile fracture ahead of the cutting tool in both OFHC Copper and Al-2024 T3. To model the cutting process with ductile fracture leading to material separation the finite element method is used. The model is implemented in a commercial finite element software using the explicit formulation. Material separation is modeled via element failure. The model is then validated using the measured cutting and thrust forces and used to study the energy consumed in cutting. As the thickness of layer removed is reduced the energy consumed in material separation becomes important. Simulations also show that the stress state ahead of the tool is favorable for ductile fracture to occur. Ductile fracture in three locations in an interface zone at the chip root is seen while cutting with edge radius tool. A hypothesis is advanced wherein an element gets wrapped around the tool edge and is stretched in two directions leading to fracture. The numerical model is then used to study the difference in stress state and energy consumption between a sharp tool and a tool with a non-zero edge radius.

The objective of this dissertation is to further the understanding of inelastic behavior in metallic materials. Despite the increasing use of polymeric composites in aircraft structures, high specific strength metals continue to be used in key components such as airframe, fuselage, wings, landing gear and hot engine parts. Design of metallic structures subjected to thermomechanical extremes in aerospace, automotive and nuclear applications requires consideration of the plasticity, creep and fracture behavior of these materials. Consideration of inelasticity and damage processes is also important in the design of metallic components used in functional applications such as thin films, flexible electronics and micro electro mechanical systems. Fracture mechanics has been largely successful in modeling damage and failure phenomena in a host of engineering materials. In the context of ductile metals, the Gurson void growth model remains one of the most successful and widely used models. However, some well documented limitations of the model in quantitative prediction of the fracture strains and failure modes at low triaxialities may be traceable to the limited representation of the damage microstructure in the model. In the first part of this dissertation, we develop an extended continuum model of void growth that takes into account details of the material microstructure such as the texture of the plastically deforming matrix and the evolution of the void shape. The need for such an extension is motivated by a detailed investigation of the effects of the two types of anisotropy on the materials' effective response using finite element analysis. The model is derived using the Hill-Mandel homogenization theory and an approximate limit analysis of a porous representative volume element. Comparisons with several numerical studies are presented towards a partial validation of the analytical model. Inelastic phenomena such as plasticity and creep result from the collective behavior of a large number of nano and micro scale defects such as dislocations, vacancies and grain boundaries. Continuum models relate macroscopically observable quantities such as stress and strain by coarse graining the discrete defect microstructure. While continuum models provide a good approximation for the effective behavior of bulk materials, several deviations have been observed in experiments at small scales such as an intrinsic size dependence of the material strength. Discrete dislocation dynamics (DD) is a mesoscale method for obtaining the mechanical response of a material by direct simulation of the motion and interactions of dislocations. The model incorporates an intrinsic length scale in the dislocation Burgers vector and potentially allows for size dependent mechanical behavior to emerge naturally from the dynamics of the dislocation ensemble. In the second part of this dissertation, a simplified two dimensional DD model is employed to study several phenomena of practical interest such as strain hardening under homogeneous deformation, growth of microvoids in a crystalline matrix and creep of single crystals at elevated temperatures. These studies have been enabled by several recent enhancements to the existing two-dimensional DD framework described in Chapter V. The main contributions from this research are: (i) development of a fully anisotropic continuum model of void growth for use in ductile fracture simulations and (ii) enhancing the capabilities of an existing two-dimensional DD framework for large scale simulations in complex domains and at elevated temperatures.

To date, efforts to model fracture and crack propagation have focused on two broad approaches: discrete and continuum damage descriptions. The discrete approach incorporates a discontinuity into the displacement field that must be tracked and updated. Examples of this approach include XFEM, element deletion, and cohesive zone models. The continuum damage, or smeared crack, approach incorporates a damage parameter into the model that controls the strength of the material. An advantage of this approach is that it does not require interface tracking since the damage parameter varies continuously over the domain. An alternative approach is to use a phase-field to describe crack propagation. In the phase-field approach to modeling fracture the problem is reformulated in terms of a coupled system of partial differential equations. A continuous scalar-valued phase-field is introduced into the model to indicate whether the material is in the unfractured or fractured ''phase''. The evolution of the phase-field is governed by a partial differential equation that includes a driving force that is a function of the strain energy of the body in question. This leads to a coupling between the momentum equation and the phase-field equation. The phase-field model also includes a length scale parameter that controls the width of the smooth approximation to the discrete crack. This allows discrete cracks to be modeled down to any desired length scale. Thus, this approach incorporates the strengths of both the discrete and continuum damage models, i.e., accurate modeling of individual cracks with no interface tracking. The research presented in this dissertation focuses on developing phase-field models for dynamic fracture. A general formulation in terms of the usual balance laws supplemented by a microforce balance law governing the evolution of the phase-field is derived. From this formulation, small-strain brittle and large-deformation ductile models are then derived. Additionally, a fourth-order theory for the phase-field approximation of the crack path is postulated. Convergence and approximation results are obtained for the proposed theories. In this work, isogeometric analysis, and particularly T-splines, plays an important role by providing a smooth basis that allows local refinement. Several numerical simulations have been performed to evaluate the proposed theories. These results show that phase-field models are a powerful tool for predicting fracture. / text

A series of experiments and finite-element simulations were performed in order to assess existing void coalescence criteria and propose a new model for the coalescence of cylindrical holes in a pure metal matrix during uniaxial stretching. The finite-element simulations were performed so that various plastic limit-load models could be evaluated at each strain increment during deformation, rendering predictions concerning the farfield strains required for coalescence. The experiments were performed in order to identify the actual far-field strain at the moment of incipient coalescence for the specimen geometries considered. The cylindrical-void models of Thomason (1990) and McClintock (1966) outperformed all of the other considered models in their original states. A modified form of the Ragab (2004) plastic limit-load model is proposed in the present work and is shown to have good agreement with the experimental results. The present model accounts for ligament work-hardening and ligament orientation.

Titanium is a widely used metal in industrial and commercial applications. It retains anisotropic mechanical properties at room temperature due to its HCP crystal structure. The effects of crystal orientation have been studied theoretically and through modeling though there is a lack of empirical data available on the topic. The work presented here uses laser-machined voids along with EBSD analysis to study the ductility of grains in different orientations to better understand the microscale fracture process in α-titanium. Experimental results show that hard grains with their c-axis parallel to the tensile direction behave in a less ductile manner than grains with their c-axis oriented away from the tensile direction. This is due to the basal slip systems activating in the former case and prismatic slip systems in the latter. Models utilized include the McClintock model for void growth, Brown-Embury model for void coalescence and FEM crystal plasticity simulations

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Titanium is a widely used metal in industrial and commercial applications. It retains anisotropic mechanical properties at room temperature due to its HCP crystal structure. The effects of crystal orientation have been studied theoretically and through modeling though there is a lack of empirical data available on the topic. The work presented here uses laser-machined voids along with EBSD analysis to study the ductility of grains in different orientations to better understand the microscale fracture process in α-titanium. Experimental results show that hard grains with their c-axis parallel to the tensile direction behave in a less ductile manner than grains with their c-axis oriented away from the tensile direction. This is due to the basal slip systems activating in the former case and prismatic slip systems in the latter. Models utilized include the McClintock model for void growth, Brown-Embury model for void coalescence and FEM crystal plasticity simulations