Finite element simulations of the cyclic elastoplastic behaviour of copper thin films

A large-scale computational and statistical strategy is presented to investigate the development of plastic strain heterogeneities and plasticity induced roughness at the free surface in multicrystalline films subjected to cyclic loading conditions, based on continuum crystal plasticity theory. The distribution of plastic strain in the grains and its evolution during cyclic straining are computed using the finite element method in films with different ratios of in-plane grain size and thickness, and as a function of grain orientation (grains with a {1 1 1} or a {0 0 1} plane parallel to the free surface and random orientations). Computations are made for 10 different realizations of aggregates containing 50 grains and one large aggregate with 225 grains. It is shown that overall cyclic hardening is accompanied by a significant increase in strain dispersion. The case of free-standing films is also addressed for comparison. The overall surface roughness is shown to saturate within 10 to 15 cycles. Plasticity induced roughness is due to the higher deformation of {0 0 1} and random grains and due to the sinking or rising at some grain boundaries.

Finite element analysis of an axi-symmetric forward spiral extrusion of Mg-1.75Mn alloy

A potential severe plastic deformation process known as axi-symmetrical forward spiral extrusion (AFSE) has been studied numerically and experimentally. The process is based on the extrusion of cylindrical samples through a die with engraved spiral grooves in a near zero shape change manner. The process was simulated using a three dimensional finite element (FE) model that has been developed using commercial software, ABAQUS. In order to verify the finite element results, hot rolled and annealed samples of the alloy were experimentally processed by AFSE. The required extrusion forces during the process were estimated using the FE model and compared with the experimental values. The reasonable agreement between the FE results and experimental data verified the accuracy of the FE model. The numerical results indicate the linear strain distribution in the AFSE sample is only valid for a core concentric while the strain distribution in the vicinity of the grooves is non axi-symmetric. The FE simulation results from this research allows a better understanding of AFSE kinematics especially near the grooves, the required extrusion force and the resultant induced strain distribution in the sample. To compare the mechanical properties of the Mg-1.75Mn alloy before and after the process, a micro shear punch test was used. The tests were performed on samples undergoing one and four passes of AFSE. After four passes of AFSE, it was observed that the average shear strength of the alloy has improved by about 21%. The developedfinite element model enables tool design and material flow simulation during the process.

Finite element analysis of plastic deformation in variable lead axisymmetric forward spiral extrusion

A modified axisymmetric forward spiral extrusion (AFSE) has been proposed recently to enhance the strain accumulation during the process. The new technique is called variable lead axisymmetric forward spiral extrusion (VLAFSE) that features a variable lead along the extrusion direction. To assess the effect of design modification on plastic deformation, a comprehensive study has been performed here using a 3D transient finite element (FE) model. The FE results established the shear deformation as the dominant mode of deformation which has been confirmed experimentally. The variable lead die extends strain accumulation in the radial and longitudinal directions over the entire grooved section of the die and eliminates the rigid body rotation which occurs in the case of a constant lead die, AFSE. A comparison of forming loads for VLAFSE and AFSE proved the advantages of the former design in the reduction of the forming load which is more pronounced under higher frictional coefficients. This finding proves that the efficiency of VLAFSE is higher than that of AFSE. Besides, the significant amount of accumulated shear strain in VLAFSE along with non-axisymmetric distribution of friction creates a surface feature in the processed sample called zipper effect that has been investigated. © 2012 Springer Science+Business Media New York.

Finite element model updating using estimation of distribution algorithm

Finite Element (FE) model updating has been attracting research attentions in structural engineering fields for over 20 years. Its immense importance to the design, construction and maintenance of civil and mechanical structures has been highly recognised. However, many sources of uncertainties may affect the updating results. These uncertainties may be caused by FE modelling errors, measurement noises, signal processing techniques, and so on. Therefore, research efforts on model updating have been focusing on tackling with uncertainties for a long time. Recently, a new type of evolutionary algorithms has been developed to address uncertainty problems, known as Estimation of Distribution Algorithms (EDAs). EDAs are evolutionary algorithms based on estimation and sampling from probabilistic models and able to overcome some of the drawbacks exhibited by traditional genetic algorithms (GAs). In this paper, a numerical steel simple beam is constructed in commercial software ANSYS. The various damage scenarios are simulated and EDAs are employed to identify damages via FE model updating process. The results show that the performances of EDAs for model updating are efficient and reliable.