A Novel Methodology to Characterize the Constitutive Behaviour of Polyethylene terephthalate for the Stretch Blow Moulding process

The stretch blow moulding (SBM) process is the main method for the mass production of PET containers. And understanding the constitutive behaviour of PET during this process is critical for designing the optimum product and process. However due to its nonlinear viscoelastic behaviour, the behaviour of PET is highly sensitive to its thermomechanical history making the task of modelling its constitutive behaviour complex. This means that the constitutive model will be useful only if it is known to be valid under the actual conditions of interest to the SBM process. The aim of this work was to develop a new material characterization method providing new data for the deformation behaviour of PET relevant to the SBM process. In order to achieve this goal, a reliable and robust characterization method was developed based on an instrumented stretch rod and a digital image correlation system to determine the stress-strain relationship of material in deforming preforms during free stretch-blow tests. The effect of preform temperature and air mass flow rate on the deformation behaviour of PET was also investigated.

Modelling the crush behaviour of thermoplastic composites

Thermoplastic composites are likely to emerge as the preferred solution for meeting the high-volume production demands of passenger road vehicles. Substantial effort is currently being directed towards the development of new modelling techniques to reduce the extent of costly and time consuming physical testing. Developing a high-fidelity numerical model to predict the crush behaviour of composite laminates is dependent on the accurate measurement of material properties as well as a thorough understanding of damage mechanisms associated with crush events. This paper details the manufacture, testing and modelling of self-supporting corrugated-shaped thermoplastic composite specimens for crashworthiness assessment. These specimens demonstrated a 57.3% higher specific energy absorption compared to identical specimen made from thermoset composites. The corresponding damage mechanisms were investigated in-situ using digital microscopy and post analysed using Scanning Electron Microscopy (SEM). Splaying and fragmentation modes were the 2 primary failure modes involving fibre breakage, matrix cracking and delamination. A mesoscale composite damage model, with new non-linear shear constitutive laws, which combines a range of novel techniques to accurately capture the material response under crushing, is presented. The force-displacement curves, damage parameter maps and dissipated energy, obtained from the numerical analysis, are shown to be in a good qualitative and quantitative agreement with experimental results. The proposed approach could significantly reduce the extent of physical testing required in the development of crashworthy structures.  

Strain gradient plasticity modelling of high-pressure torsion

Gradient plasticity modelling combining a micro-structure-related constitutive description of the local material behaviour with a particular gradient plasticity frame is presented. The constitutive formulation is based on a phase mixture model in which the dislocation cell walls and the cell interiors are considered as separate 'phases', the respective dislocation densities entering as internal variables. Two distinct physical mechanisms, which give rise to gradient plasticity, are considered. The first one is associated with the occurrence of geometrically necessary dislocations leading to first-order strain gradients; the second one is associated with the reaction stresses due to plastic strain incompatibilities between neighbouring grains, which lead to second-order strain gradients. These two separate variants of gradient plasticity were applied to the case of high-pressure torsion: a process known to result in a fairly uniform, ultrafine grained structure of metals. It is shown that the two complementary variants of gradient plasticity can both account for the experimental results, thus resolving a controversial issue of the occurrence of a uniform micro-structure as a result of an inherently non-uniform process. © 2007 Elsevier Ltd. All rights reserved.