Tamer El Sayed

Ultrasonic-assisted manufacturing processes: Variational model and numerical simulations

We present a computational study of ultrasonic assisted manufacturing processes including sheet metal forming, upsetting, and wire drawing. A fully variational porous plasticity model is modified to include ultrasonic softening effects and then utilized to account for instantaneous softening when ultrasonic energy is applied during deformation. Material model parameters are identified via inverse modeling, i.e. by using experimental data. The versatility and predictive ability of the model are demonstrated and the effect of ultrasonic intensity on the manufacturing process at hand is investigated and compared qualitatively with experimental results reported in the literature.

Crack density and electrical resistance in indium-tin-oxide/polymer thin films under cyclic loading

AbstractHere, we propose a damage model that describes the degradation of the material properties of indium-tin-oxide (ITO) thin films deposited on polymer substrates under cyclic loading. We base this model on our earlier tensile test model and show that the new model is suitable for cyclic loading. After calibration with experimental data, we are able to capture the stress-strain behavior and changes in electrical resistance of ITO thin films. We are also able to predict the crack density using calibrations from our previous model. Finally, we demonstrate the capabilities of our model based on simulations using material properties reported in the literature. Our model is implemented in the commercially available finite element software ABAQUS using a user subroutine UMAT.

A variational constitutive model for the distribution and interactions of multi-sized voids

The evolution of defects or voids, generally recognized as the basic failure mechanism in most metals and alloys, has been intensively studied. Most investigations have been limited to spatially periodic cases with non-random distributions of the radii of the voids. In this study, we use a new form of the incompressibility of the matrix to propose the formula for the volumetric plastic energy of a void inside a porous medium. As a consequence, we are able to account for the weakening effect of the surrounding voids and to propose a general model for the distribution and interactions of multi-sized voids. We found that the single parameter in classical Gurson-type models, namely void volume fraction is not sufficient for the model. The relative growth rates of voids of different sizes, which can in principle be obtained through physical or numerical experiments, are required. To demonstrate the feasibility of the model, we analyze two cases. The first case represents exactly the same assumption hidden in the classical Gurson’s model, while the second embodies the competitive mechanism due to void size differences despite in a much simpler manner than the general case. Coalescence is implemented by allowing an accelerated void growth after an empirical critical porosity in a way that is the same as the Gurson–Tvergaard–Needleman model. The constitutive model presented here is validated through good agreements with experimental data. Its capacity for reproducing realistic failure patterns is shown by simulating a tensile test on a notched round bar.

Prediction of crack density and electrical resistance changes in indium tin oxide/polymer thin films under tensile loading

We present unified predictions for the crack onset strain, evolution of crack density, and changes in electrical resistance in indium tin oxide/polymer thin films under tensile loading. We propose a damage mechanics model to quantify and predict such changes as an alternative to fracture mechanics formulations. Our predictions are obtained by assuming that there are no flaws at the onset of loading as opposed to the assumptions of fracture mechanics approaches. We calibrate the crack onset strain and the damage model based on experimental data reported in the literature. We predict crack density and changes in electrical resistance as a function of the damage induced in the films. We implement our model in the commercial finite element software ABAQUS using a user subroutine UMAT. We obtain fair to good agreement with experiments.

A hybrid, massively parallel implementation of a genetic algorithm for optimization of the impact performance of a metal/polymer composite plate

A hybrid parallelization method composed of a coarse-grained genetic algorithm (GA) and fine-grained objective function evaluations is implemented on a heterogeneous computational resource consisting of 16 IBM Blue Gene/P racks, a single x86 cluster node and a high-performance file system. The GA iterator is coupled with a finite-element (FE) analysis code developed in house to facilitate computational steering in order to calculate the optimal impact velocities of a projectile colliding with a polyurea/structural steel composite plate. The FE code is capable of capturing adiabatic shear bands and strain localization, which are typically observed in high-velocity impact applications, and it includes several constitutive models of plasticity, viscoelasticity and viscoplasticity for metals and soft materials, which allow simulation of ductile fracture by void growth. A strong scaling study of the FE code was conducted to determine the optimum number of processes run in parallel. The relative efficiency of the hybrid, multi-level parallelization method is studied in order to determine the parameters for the parallelization. Optimal impact velocities of the projectile calculated using the proposed approach, are reported.

Constitutive modeling of stress-driven grain growth in nanocrystalline metals

In this work, we present a variational multiscale model for grain growth in face-centered cubic nanocrystalline (nc) metals. In particular, grain-growth-induced stress softening and the resulting relaxation phenomena are addressed. The behavior of the polycrystal is described by a conventional Taylor-type averaging scheme in which the grains are treated as two-phase composites consisting of a grain interior phase and a grain boundary-affected zone. Furthermore, a grain-growth law that captures the experimentally observed characteristics of the grain coarsening phenomena is proposed. To this end, the grain size is not taken as constant and varies according to the proposed stress-driven growth law. Several parametric studies are conducted to emphasize the influence of the grain-growth rule on the overall macroscopic response. Finally, the model is shown to provide a good description of the experimentally observed grain-growth-induced relaxation in nc-copper.