Olivier Pantalé

Numerical implementation of the eXtended Finite Element Method for dynamic crack analysis

A numerical implementation of the eXtended Finite Element Method (X-FEM) to analyze crack propagation in a structure under dynamic loading is presented in this paper. The arbitrary crack is treated by the X-FEM method without re-meshing but using an enrichment of the classical displacement-based finite element approximation in the framework of the partition of unity method. Several algorithms have been implemented, within an oriented object framework in C++, in the home made explicit FEM code. The new module, called DynaCrack, included in the dynamic FEM code DynELA, evaluates the crack geometry, the propagation of the crack and allow the post-processing of the numerical results. The module solves the system of discrete equations using an explicit integration scheme. Some numerical examples illustrating the main features and the computational efficiency of the DynaCrack module for dynamic crack propagation are presented in the last section of the paper.

A numerical simulation of steady state metal cutting

Abstract An arbitrary Lagrangian-Eulerian (ALE) approach is used to model the orthogonal metal cutting in a steady state situation. The thermomechanical model includes the effects of elasticity, plasticity, strain rate, large strains and friction with heat generated between the tool and the chip. The ALE formulation can combine the advantages of both the Eulerian and Lagrangian approaches in a single description. Particularly, problems linked to the free surface in a Eulerian description and those linked to severe mesh distortions in a Lagrangian one can be solved by this formulation. The ALE governing equations are briefly reviewed in this paper; finite element and finite volume methods are used for the discretization of the conservation equations and an explicit time integration is adopted. Only the steady state solution is required; the ALE formulation is exploited to update the free and the contact surfaces. The model predicts the thermomechanical quantities, the chip geometry and the cutting forces from the cutting data and the material and friction parameters. Cutting experiments were performed with 42CD4 steel and comparisons of experimental tool forces and chip geometry with the numerical results are presented.

Anisotropic unilateral damage with initial orthotropy: A micromechanics-based approach

A micromechanics-based damage model able to describe the brittle response of initially anisotropic materials is presented. A special emphasis is put on the account of damage-induced anisotropy and unilateral behaviour related to microcracks closure effects. These both features clearly influence the inelastic deformation of microcracked materials and lead to even more complex consequences in the context of initial anisotropy. The aim of this work is then to derive a new strain-based formulation which allows representing the related interactions between all these phenomena. This is achieved through a recent two-dimensional energy-based micromechanical analysis that accounts for the fully anisotropic multilinear response of orthotropic materials weakened by arbitrarily oriented microcracks. On the other hand, the thermodynamics framework gives a standard procedure for the development of the damage evolution law. Throughout the paper, attention is put on the mathematical and thermodynamical consistency of the model to avoid difficulties usually associated to the simultaneous description of damage-induced anisotropy and unilateral effects. In addition to elastic constants, the model requires the identification of only two parameters related to damage evolution. The model has been implemented within the commercial finite-element code ABAQUS, and various numerical simulations are presented to illustrate its capabilities. Especially, evolution of the material symmetry and influence of opening-closure states of microcracks on the damage process are illustrated in the case of brittle matrix composites subjected to different loading cases (axis and off-axis loads, tension and compression, tension followed by compression).

Effect of Ductile Damage Evolution in Sheet Metal Forming: Experimental and Numerical Investigations

The numerical simulation based on the Finite Element Method (FEM) is widely used in academic institutes and in the industry. It is a useful tool to predict many phenomena present in the classical manufacturing forming processes such as necking, fracture, springback, buckling and wrinkling. But, the results of such numerical model depend strongly on the parameters of the constitutive behavior model. In the first part of this work, we focus on the traditional identification of the constitutive law using oriented tensile tests (0°, 45°, and 90° with respect to the rolling direction). A Digital Image Correlation (DIC) method is used in order to measure the displacements on the surface of the specimen and to analyze the necking evolution and the instability along the shear band. Therefore, bulge tests involving a number of die shapes (circular and elliptic) were developed. In a second step, a mixed numerical–experimental method is used for the identification of the plastic behavior of the stainless steel metal sheet. The initial parameters of the inverse identification were extracted from a uniaxial tensile test. The optimization procedure uses a combination of a Monte-Carlo and a Levenberg-Marquardt algorithm. In the second part of this work, according to some results obtained by SEM (Scaning Electron Microscopy) of the crack zones on the tensile specimens, a Gurson Tvergaard Needleman (GTN) ductile model of damage has been selected for the numerical simulations. This model was introduced in order to give informations concerning crack initiations during hydroforming. At the end of the paper, experimental and numerical comparisons of sheet metal forming applications are presented and validate the proposed approach.

Finite Element Simulation of Low Velocity Impact Damage on an Aeronautical Carbon Composite Structure

Low velocity barely visible impact damage (BVID) in laminated carbon composite structures has a major importance for aeronautical industries. This contribution leads with the development of finite element models to simulate the initiation and the propagation of internal damage inside a carbon composite structure due by a low velocity impact. Composite plates made from liquid resin infusion process (LRI) have been subjected to low energy impacts (around 25 J) using a drop weight machine. In the experimental procedure, the internal damage is evaluated using an infrared thermographic camera while the indentation depth of the face is measured by optical measurement technique. In a first time we developed a robust model using homogenised shells based on degenerated tri-dimensional brick elements and in a second time we decided to modelize the whole stacking sequence of homogeneous layers and cohesive interlaminar interfaces in order to compare and validate the obtained results. Both layer and interface damage initiation and propagation models based on the Hashin and the Benzeggagh-Kenane criteria have been used for the numerical simulations. Comparison of numerical results and experiments has shown the accuracy of the proposed models.

Brittle Damage in Initially Anisotropic Materials: A Model Accounting for the Induced Anisotropy and Unilateral Effects

A new micromechanical modelling approach for brittle damage in initially orthotropic materials is presented. The proposed strain-based energy formulation allows to derive a fully anisotropic multilinear model for microcracked materials with arbitrary oriented defects. The thermodynamics framework provides a standard procedure for the damage evolution law. The new model explicitly accounts for the interaction between primary and induced anisotropies. Moreover, the very challenging issue of opening-closure effects (unilateral behavior) is addressed in this framework.

Approaches to simulate impact damages on aeronautical composite structures

Impact damage is one of the most critical aggressions for composite structures in aeronautical applications. Consequences of a high/low velocity and high/low energy impacts are very important to investigate. It is usually admitted that the most critical configuration is the Barely Visible Impact Damage (BVID), with impact energy of about 25 J, where some internal damages, invisible on the impacted surface of the specimen, drastically reduce the residual properties of the impacted material. In this work we highlight by the finite element simulation, the damage initiation and propagation process and the size of the defaults created by low velocity impact. Two approaches were developed: the first one is the layup technic and the second one is based on the cohesive element technic. Both technics show the plies damages by the Hashin’s criteria. Moreover the second one gives the delamination damages with regards to the Benzeggah-Kenane criteria. The validation of these models is done by confrontation with some experimental results.

Multiscale structure of nacre biomaterial: Thermomechanical behavior and wear processes

Sheet nacre is a hybrid biocomposite with a multiscale structure, including nanograins of CaCO3 (97% wt% - 40 nm in size) and two organic matrices: (i) the interlamellar mainly composed of β-chitin and proteins, and (ii) the intracrystalline composed by silk-fibroin-like proteins. This material is currently contemplated for the manufacture of small prostheses (e.g., rachis and dorsal vertebra prostheses) which are subjected to micro-slip or fretting motion. In this work, the tribological behavior of nacre is studied by varying the frictional dissipated power from few nW to several hundred mW, in order to assess the various responses of the different nacres components, independently. Results reveal various dissipative mechanisms vs. dissipated frictional power: organic thin film lubrication, tablets elastoplastic deformations, stick-slip phenomenon and/or multiscale wear processes, including various thermo-mechanical processes (i.e., mineral phase transformation, organics melting and friction-induced nanoshocks process on a large range). All these mechanisms are controlled by the multiscale and anisotropy of its structure - and especially by its both matrices and respective orientation vs. the sliding direction.

Influence of Process and Material Parameters on Impact Response in Composite Structure: Methodology Using Design of Experiments

Even if the mechanical performances of composite materials give new perspectives for the aircraft and space design, the variability of their behavior, linked to the presence of initial microscopic defects or led in service, constitute however a still important brake in their development. As regards particularly the response to fatigue loads or ageing, the behavior of these materials is affected by several sources of uncertainties, notably on the nature of the physical mechanisms of degradation, which are translated by a strong dispersion in life time. In aerospace industry, low energy impact phenomenon is not well known concerning composite materials and composite structures. Many manufacturers use important safety factors to design structures. The aim of this work is to define the most predominant parameters which permit a good response of damage using experiences plans. The differences of these parameters by using Resin Transfer Molding (RTM) or Liquid Resin Infusion (LRI) process than prepreg one is also studied in this work.

A methodology for large scale finite element models, including multi-physic, multi-domain and multi-timestep aspects

This works concerns the development of a virtual prototyping tool dedicated to electro-thermo-mechanical simulation of power converters. The FEM code, written using an object-oriented language, includes a dual Schur Domain Decomposition Method. The solving of problems including floating subdomains can be performed in steady-state cases, whereas one can couple multi-timestep implicit and explicit integration schemes in transient analysis. The last part of this work is about the study of an industrial benchmark concerning the power converters used in railway transport: the electro-thermal simulation of a switch in transient analysis. This example allows to compare different strategies of tearing into subdomains and the use of different timesteps on the same structure.