M. Heitzer

LISA : a European project for FEM-based limit and shakedown analysis

The load-carrying capacity or the safety against plastic limit states are the central questions in the design of structures and passive components in the apparatus engineering. A precise answer is most simply given by limit and shakedown analysis. These methods can be based on static and kinematic theorems for lower and upper bound analysis. Both may be formulated as optimization problems for finite element discretizations of structures. The problems of large-scale analysis and the extension towards realistic material modelling will be solved in a European research project. Limit and shakedown analyses are briefly demonstrated with illustrative examples.

Basis Reduction for the Shakedown Problem for Bounded Kinematic Hardening Material

Limit and shakedown analysis are effective methods for assessing the load carrying capacity of a given structure. The elasto–plastic behavior of the structure subjected to loads varying in a given load domain is characterized by the shakedown load factor, defined as the maximum factor which satisfies the sufficient conditions stated in the corresponding static shakedown theorem. The finite element dicretization of the problem may lead to very large convex optimization. For the effective solution a basis reduction method has been developed that makes use of the special problem structure for perfectly plastic material. The paper proposes a modified basis reduction method for direct application to the two-surface plasticity model of bounded kinematic hardening material. The considered numerical examples show an enlargement of the load carrying capacity due to bounded hardening.

FEM-computation of load carrying capacity of highly loaded passive components by direct methods

Limit and shakedown theorems are exact theories of classical plasticity for the direct computation of safety factors or of the load carrying capacity under constant and varying loads. Simple versions of limit and shakedown analysis are the basis of all design codes for pressure vessels and pipings. Using finite element methods (FEM), more realistic modeling can be used for a more rational design. The methods can be extended towards optimum plastic design. In this paper, we present a first implementation of limit and shakedown analyses for perfectly plastic material into a general purpose FEM program. Limit and shakedown loads are obtained for a square plate with a hole and for a thin tube. Interaction diagrams are calculated and the results are compared with known analytic solutions.

Cyclic plastic deformation tests to verify FEM-based shakedown analyses

Fatigue analyses are conducted with the aim of verifying that thermal ratcheting is limited. To this end it is important to make a clear distintion between the shakedown range and the ratcheting range (continuing deformation). As part of an EU-supported research project, experiments were carried out using a 4-bar model. The experiment comprised a water-cooled internal tube, and three insulated heatable outer test bars. The system was subjected to alternating axial forces, superimposed with alternating temperatures at the outer bars. The test parameters were partly selected on the basis of previous shakedown analyses. During the test, temperatures and strains were measured as a function of time. The loads and the resulting stresses were confirmed on an ongoing basis during performance of the test, and after it. Different material models were applied for this incremental elasto-plastic analysis using the ANSYS program. The results of the simulation are used to verify the FEM-based shakedown analysis.

Reliability Analysis of Elasto-Plastic Structures under Variable Loads

Structural reliability analysis is based on the concept of a limit state function separating failure from safe states of a structure. The paper discusses some difficulties of different reliability methods for FEM-discretized nonlinear structures. It is proposed that theorems of limit and shakedown analysis are used for a direct definition of the limit state function for failure by plastic collapse or by inadaptation. Shakedown describes an asymptotic and therefore time invariant structural behaviour under time variant loading. The limit state function and its gradient is obtained from a mathematical optimization problem. For application to large FEM models a basis reduction method is used. The method is implemented into a general purpose FEM code. Combined with FORM highly effective, robust and precise analyses could be performed for high-reliabilty problems.

Shakedown and ratchetting under tension–torsion loadings: analysis and experiments

Structural design analyses are conducted with the aim of verifying the exclusion of ratchetting. To this end it is important to make a clear distinction between the shakedown range and the ratchetting range. The performed experiment comprised a hollow tension specimen which was subjected to alternating axial forces, superimposed with constant moments. First, a series of uniaxial tests has been carried out in order to calibrate a bounded kinematic hardening rule. The load parameters have been selected on the basis of previous shakedown analyses with the PERMAS code using a kinematic hardening material model. It is shown that this shakedown analysis gives reasonable agreement between the experimental and the numerical results. A linear and a nonlinear kinematic hardening model of two-surface plasticity are compared in material shakedown analysis.

Structural Optimization with FEM-based Shakedown Analyses

In this paper, a mathematical programming formulation is presented for the structural optimization with respect to the shakedown analysis of 3-D perfectly plastic structures on basis of a finite element discretization. A new direct algorithm using plastic sensitivities is employed in solving this optimization formulation. The numerical procedure has been applied to carry out the shakedown analysis of pipe junctions under multi-loading systems. The new approach is compared to so-called derivative-free direct search methods. The computational effort of the proposed method is much lower compared to this methods.