The mesomechanics behavior of a polycrystalline microstructure subjected to creep and constant strain rate loadings is investigated. The analysis is based on a Voronoi polygonization strategy for the generation of grains, that are bonded to each other via interfaces along the grain boundaries. A new constitutive model is proposed for the rate-dependent debonding along these interfaces, whereby damage is kinetically coupled to viscoplastic slip and dilatation. The paper may be viewed as generalizing the rate-independent model used in Cannmo et al. (1995).

The mesomechanics behavior of a polycrystalline microstructure subjected to creep and constant strain rate loadings is investigated. The analysis is based on a Voronoi polygonization strategy for the generation of grains, that are bonded to each other via interfaces along the grain boundaries. A new constitutive model is proposed for the rate-dependent debonding along these interfaces, whereby damage is kinetically coupled to viscoplastic slip and dilatation. The paper may be viewed as generalizing the rate-independent model used in Cannmo et al. (1995).

The mesomechanical behavior of a polycrystalline microstructure subjected to monotonic and cyclic loadings is investigated. The analysis is based on a Voronoi polygonization strategy for generation of grains embedded in a contiguous matrix. The main emphasis is to investigate the interaction between the microconstituents and the failure processes along grain boundaries. A rational interface theory based on damage development coupled to inelastic slip and dilatation is developed. The theory uses the interface width as a constitutive parameter, which regularizes the theory of LEMAITRE [1992], that is restricted to perfect bond between grain and matrix. In a series of FE-analyses parameter variations were performed. The unit cell size (as compared to the average grain diameter), the grain-matrix area ratio, the interface width and constitutive parameters. It appears that the composite behavior can be designed as brittle or ductile solely depending on the strength and rate of damage development in the interfaces. A localization band was detected, and its orientation is in the range that is predicted within continuum theory

Several types of dynamic tests are carried out at SP Swedish National Testing and Research Institute. The tests considered in this paper, which are all simulated with FE-calculations, are as follows: a drop test of cask filled with water, a tennis racket/ball test, a test of a full face protector for hockey players and an impact test of a simplified bumper. To obtain a high-quality verification of the FE-results high-speed video recording of the test sequence is done in all four cases. Parameter studies are done regarding velocity and drop height. The FE-models are built up in the commercial software ABAQUS and I-deas, and are all solved numerically with ABAQUS/Explicit. The material models used in the FE-calculations include linear elastic, elastic-plastic with non-linear hardening, hyperelastic and linear hydrodynamic behavior. Different types of tests are carried out on material specimens in order to determine the material parameters used in the FE-models.

In this work residual stresses in a stress lattice are studied. The residual stresses are both measured and simulated. The stress lattice is casted of low alloyed grey cast iron. In fact, nine similar lattices are casted and measured. The geometry of the lattice consists of three sections in parallel. The diameter of the two outer sections are thinner than the section in the middle. When the stress lattice cools down, this difference in geometry yields that the outer sections start to solidify and contract before the section in the middle. Finally, an equilibrium state, with tensile stresses in the middle and compressive stresses in the outer sections, is reached. The thermo-mechanical simulation of the experiments is performed by using Abaqus. The thermo-mechanical solidification is assumed to be uncoupled. First a thermal analysis, where the lattice is cooled down to room temperature, is performed. Latent heat is included in the analysis by letting the fraction of solid be a linear function of the temperature in the mushy zone. After the thermal analysis a quasi-static mechanical analysis is performed where the temperature history is considered to be the external force. A rate independent J₂-plasticity model with isotropic hardening is considered, where the material data depend on the temperature. Tensile tests are performed at room temperature, 200°C, 400°C, 600°C and 800°C in order to evaluate the Young´s modulus, the yield strength and the hardening accurate. In addition, the thermal expansion coefficient is evaluated for temperatures between room temperature and 1000°C. The state of residual stresses is measured by cutting the mid section or the outer section. The corresponding elastic spring-back reveals the state of residual stresses. The measured stresses are compared to the numerical simulations. The simulations show good agreement with the results from the experiments.

In this work a hybrid method of a genetic algorithm  and sequential linear programming is suggested to obtain a D-optimal design of experiments. Regular as well as non-regular design spaces are considered. A D-optimal design of experiments maximizes the determinant of the information matrix, which appears in the normal equation. It is known that D-optimal design of experiments sometimes include duplicate design points. This is, of course, not preferable since duplicates do not add any new information to the response surface approximation and the computational effort is therefore wasted. In this work a Bayesian modification, where higher order terms are added to the response surface approximation, is used in case of duplicates in the design of experiments. In such manner, the draw-back with duplicates might be eliminated. The D-optimal problem, which is obtained by using the Bayesian modification, is then solved by a hybrid method. A hybrid method of a genetic algorithm that generates a starting point for sequential linear programming is developed. The genetic algorithm performs genetic operators such as cross-over and mutation on a binary version of the design of experiments, while the real valued version is used to evaluate the fitness. Next, by taking the gradient of the objective, a LP-problem is formulated which is solved by an interior point method that is available in Matlab. This is repeated in a sequence until convergence is reached. The hybrid method is tested for four numerical examples. Results from the numerical examples show a very robust convergence to a global optimum. Furthermore, the results show that the problem with duplicates is eliminated by using the Bayesian modification.

In this work the robustness of residual stresses in finite element simulations with respect to deviations in mechanical parameters in castings is evaluated. Young's modulus, the thermal expansion coefficient and the hardening are the studied parameters. A 2D finite element model of a stress lattice is used. The robustness is evaluated by comparing purely finite element based Monte Carlo simulations and Monte Carlo simulations based on linear and quadratic response surfaces. Young's modulus, the thermal expansion coefficient and the hardening are assumed to be normal distributed with a standard deviation that is 10% of their nominal value at different temperatures. In this work an improved process window is also suggested to show the robustness graphically. By using this window it is concluded that least robustness is obtained for high hardening values in combination to deviations in Young's modulus and the thermal expansion coefficient. It is also concluded that quadratic response surface based Monte Carlo simulations substitute finite element based Monte Carlo simulations satisfactory. Furthermore, the standard deviation of the responses are evaluated analytically by using the Gauss formula, and are compared to results from Monte Carlo simulations. The analytical solutions are accurate as long as the Gauss formula is not utilized close to a stationary point.

In the past stamping dies have in principle been designed by rules of thumb and intuition. As the sheet metals in the vehicle industry have got increased mechanical properties in recent years the demands on the stamping dies have increased. For instance increase in stiffness is desirable in order to better control spring-back. The most simple way to satisfy this new demand would be to make the stamping dies even more heavy in order to be able to handle the new sheet metals. Since there are restrictions of the weight of the stamping dies in the stamping machines and since the overhead cranes usually have reached the limit of what they can handle, this is not a desirable solution. Another approach, in order to increase the stiffness without increasing the weight is to use topology optimization. Recently in a master thesis at Volvo Car Corporation a conceptual design of a stamping die has been done by topology optimization. In that work no consideration is taken to the fact that the stamping die is casted. Casting implies that residual stresses possibly are produced during the solidification and cooling process. The residual stresses might affect the fatigue life and the risk of failure of the stamping die.

In this work the residual stress state after casting is analyzed for the original stamping die as well as the optimized stamping die from the master thesis discussed above. The analyses are performed using an uncoupled approach, where one thermal analysis is followed by a quasi-static elasto-plastic analysis. The thermal analysis simulates the solidification and cooling during the casting process, while the quasi-static elasto-plastic analysis uses the temperature history, obtained from the thermal analysis, in order to build up residual stresses. The thermal analysis includes the release of latent heat. Furthermore, the material properties included in the heat equation (density, conductivity, specific heat) are given as temperature dependent properties for the mould as well as the casting. In the quasi-static elasto-plastic analysis the plasticity is described by the von Mises yield surface in combination with isotropic hardening and the mechanical properties (thermal expansion coefficient, Young's modulus, yield stress, hardening parameter, Poisson's ratio) are given as temperature dependent properties. The simulations show high levels of residual stresses.

In this paper an implicit method for frictional contact, impact and rolling is suggested. A nonclassical formulation of a two-dimensional hyperelastic body unilaterally constrained to rigid supports is proposed by following the ideas of Moreau and Jean. A total Lagrangian formulation of the system is given. The elastic properties are defined by coupling the second Piola–Kirchhoff stress to the Green–Lagrange strain via the Kirchhoff–St. Venant law. The equation of motion is written in the spirit of Moreau by using the mean value impulses introduced by Jean. The mean value impulses appear explicitly in the equation of motion. In such manner the treatment of nonconstant kinematic transformation matrices becomes straightforward. The rigid supports are described by smooth functions. By utilizing these functions and the mean value impulses, new contact/impact laws of Signorini and Coulomb type are formulated. The governing equations are solved by a nonsmooth Newton method. This is performed by following the augmented Lagrangian approach and deriving the consistent stiffness matrix as well as the contact stiffness matrices. Three two-dimensional examples are solved by the method: a contact problem, an impact problem and a rolling contact problem.