Analytical model and experimental validation of friction laws for composites under low loads

In order to account for interfacial friction of composite materials, an analytical model based on contact geometry and local friction is proposed. A contact area includes several types of microcontacts depending on reinforcement materials and their shape. A proportion between these areas is defined by in-plane contact geometry. The model applied to a fibre-reinforced composite results in the dependence of friction on surface fibre fraction and local friction coefficients. To validate this analytical model, an experimental study on carbon fibrereinforced epoxy composites under low normal pressure was performed. The effects of fibre volume fraction and fibre orientation were studied, discussed and compared with analytical model results. © Springer Science+Business Media, LLC 2012.

Force chains, friction, and flow: Behavior of granular media across length scales

We study the behavior of granular materials at three length scales. At the smallest length scale, the grain-scale, we study inter-particle forces and "force chains". Inter-particle forces are the natural building blocks of constitutive laws for granular materials. Force chains are a key signature of the heterogeneity of granular systems. Despite their fundamental importance for calibrating grain-scale numerical models and elucidating constitutive laws, inter-particle forces have not been fully quantified in natural granular materials. We present a numerical force inference technique for determining inter-particle forces from experimental data and apply the technique to two-dimensional and three-dimensional systems under quasi-static and dynamic load. These experiments validate the technique and provide insight into the quasi-static and dynamic behavior of granular materials.

At a larger length scale, the mesoscale, we study the emergent frictional behavior of a collection of grains. Properties of granular materials at this intermediate scale are crucial inputs for macro-scale continuum models. We derive friction laws for granular materials at the mesoscale by applying averaging techniques to grain-scale quantities. These laws portray the nature of steady-state frictional strength as a competition between steady-state dilation and grain-scale dissipation rates. The laws also directly link the rate of dilation to the non-steady-state frictional strength.

At the macro-scale, we investigate continuum modeling techniques capable of simulating the distinct solid-like, liquid-like, and gas-like behaviors exhibited by granular materials in a single computational domain. We propose a Smoothed Particle Hydrodynamics (SPH) approach for granular materials with a viscoplastic constitutive law. The constitutive law uses a rate-dependent and dilation-dependent friction law. We provide a theoretical basis for a dilation-dependent friction law using similar analysis to that performed at the mesoscale. We provide several qualitative and quantitative validations of the technique and discuss ongoing work aiming to couple the granular flow with gas and fluid flows.

A novel measurement of dynamic friction

A tribometer, based on a pin-on-disc machine, uses a PZT drive to produce small sinusoidal fluctuations of sliding speed. The frequency and amplitude of these fluctuations can be controlled, and the dynamic response measured. Preliminary test results show that the dynamic friction variation is influenced by the contact materials, normal force, oscillation frequency and steady sliding speed. The variation of friction force amplitude and phase with frequency gives clues about the underlying state variables determining the friction. Modelling studies illustrate the expected behaviour for idealized friction laws governed by, for example, sliding speed, contact temperature, and "rate-state" laws. © 2008 SAE International.

A novel measurement of dynamic friction

A tribometer, based on a pin-on-disc machine, uses a PZT drive to produce small sinusoidal fluctuations of sliding speed. The frequency and amplitude of these fluctuations can be controlled, and the dynamic response measured. Preliminary test results show that the dynamic friction variation is influenced by the contact materials, normal force, oscillation frequency and steady sliding speed. The variation of friction force amplitude and phase with frequency gives clues about the underlying state variables determining the friction. Modelling studies illustrate the expected behaviour for idealized friction laws governed by, for example, sliding speed, contact temperature, and "rate-state" laws. © 2008 SAE International.

Numerical modelling of lubricated foil rolling

A model of lubricated cold strip rolling (1, 2) is extended to the thin foil regime. The model considers the evolution of asperity geometry and lubricant pressure through the bite, treating the strip using a conventional slab model. The elastic deflections of the rolls are coupled into the problem using an elastic finite element model. Friction between the roll and the asperities on the strip is modelled using the Coulomb and Tresca friction factor approaches. The shear stress in the Coulomb friction model is limited to the shear yield stress of the strip. A novel modification to these standard friction laws is used to mimic slipping friction in the reduction regions and sticking friction in a central neutral zone. The model is able to reproduce the sticking and slipping zones predicted by Fleck et al. (3). The variation of rolling load, lubricant film thickness and asperity contact area with rolling speed is examined, for conditions typical of rolling aluminium foil from a thickness of 50 to 25 μm. T he contact area and hence friction rises as the speed drops, leading to a large increase in rolling load. This increase is considerably more marked using Coulomb friction as compared with the friction factor approach. Forward slip increases markedly as the speed falls and a significant sticking region develops.

Nonlinear drillstring dynamics analysis

This paper studies the dynamical response of a rotary drilling system with a drag bit, using a lumped parameter model that takes into consideration the axial and torsional vibration modes of the bit. These vibrations are coupled through a bit-rock interaction law. At the bit-rock interface, the cutting process introduces a state-dependent delay, while the frictional process is responsible for discontinuous right-hand sides in the equations governing the motion of the bit. This complex system is characterized by a fast axial dynamics compared to the slow torsional dynamics. A dimensionless formulation exhibits a large parameter in the axial equation, enabling a two-time-scales analysis that uses a combination of averaging methods and a singular perturbation approach. An approximate model of the decoupled axial dynamics permits us to derive a pseudoanalytical expression of the solution of the axial equation. Its averaged behavior influences the slow torsional dynamics by generating an apparent velocity weakening friction law that has been proposed empirically in earlier work. The analytical expression of the solution of the axial dynamics is used to derive an approximate analytical expression of the velocity weakening friction law related to the physical parameters of the system. This expression can be used to provide recommendations on the operating parameters and the drillstring or the bit design in order to reduce the amplitude of the torsional vibrations. Moreover, it is an appropriate candidate model to replace empirical friction laws encountered in torsional models used for control. © 2009 Society for Industrial and Applied Mathematics.

Links between energy dissipation and wear mechanisms in solid epoxy/epoxy sliding contact

This paper covers wear and energy dissipation of solid epoxy induced by the alternative rubbing between two samples of identical thermosetting polymer. Varying normal load, sliding velocity and sliding distance, the authors were able to define and discuss wear and friction laws and associated energy dissipation. Moreover, traces of several wear mechanisms were distinguished on the worn surfaces and associated with applied conditions. Observed under higher velocity, polymer softening and local state transition were explained by surface temperature estimate and confirmed by infra-red spectroscopy measurements. To conclude this study, all observed phenomena are classified into two wear scenarios according to sliding velocity. © 2014 Elsevier Ltd.

Development of numerical methodologies for parameter identification and shape optimization in metal forming simulations

Por parte da indústria de estampagem tem-se verificado um interesse crescente em simulações numéricas de processos de conformação de chapa, incluindo também métodos de engenharia inversa. Este facto ocorre principalmente porque as técnicas de tentativa-erro, muito usadas no passado, não são mais competitivas a nível económico. O uso de códigos de simulação é, atualmente, uma prática corrente em ambiente industrial, pois os resultados tipicamente obtidos através de códigos com base no Método dos Elementos Finitos (MEF) são bem aceites pelas comunidades industriais e científicas Na tentativa de obter campos de tensão e de deformação precisos, uma análise eficiente com o MEF necessita de dados de entrada corretos, como geometrias, malhas, leis de comportamento não-lineares, carregamentos, leis de atrito, etc.. Com o objetivo de ultrapassar estas dificuldades podem ser considerados os problemas inversos. No trabalho apresentado, os seguintes problemas inversos, em Mecânica computacional, são apresentados e analisados: (i) problemas de identificação de parâmetros, que se referem à determinação de parâmetros de entrada que serão posteriormente usados em modelos constitutivos nas simulações numéricas e (ii) problemas de definição geométrica inicial de chapas e ferramentas, nos quais o objetivo é determinar a forma inicial de uma chapa ou de uma ferramenta tendo em vista a obtenção de uma determinada geometria após um processo de conformação. São introduzidas e implementadas novas estratégias de otimização, as quais conduzem a parâmetros de modelos constitutivos mais precisos. O objetivo destas estratégias é tirar vantagem das potencialidades de cada algoritmo e melhorar a eficiência geral dos métodos clássicos de otimização, os quais são baseados em processos de apenas um estágio. Algoritmos determinísticos, algoritmos inspirados em processos evolucionários ou mesmo a combinação destes dois são usados nas estratégias propostas. Estratégias de cascata, paralelas e híbridas são apresentadas em detalhe, sendo que as estratégias híbridas consistem na combinação de estratégias em cascata e paralelas. São apresentados e analisados dois métodos distintos para a avaliação da função objetivo em processos de identificação de parâmetros. Os métodos considerados são uma análise com um ponto único ou uma análise com elementos finitos. A avaliação com base num único ponto caracteriza uma quantidade infinitesimal de material sujeito a uma determinada história de deformação. Por outro lado, na análise através de elementos finitos, o modelo constitutivo é implementado e considerado para cada ponto de integração. Problemas inversos são apresentados e descritos, como por exemplo, a definição geométrica de chapas e ferramentas. Considerando o caso da otimização da forma inicial de uma chapa metálica a definição da forma inicial de uma chapa para a conformação de um elemento de cárter é considerado como problema em estudo. Ainda neste âmbito, um estudo sobre a influência da definição geométrica inicial da chapa no processo de otimização é efetuado. Este estudo é realizado considerando a formulação de NURBS na definição da face superior da chapa metálica, face cuja geometria será alterada durante o processo de conformação plástica. No caso dos processos de otimização de ferramentas, um processo de forjamento a dois estágios é apresentado. Com o objetivo de obter um cilindro perfeito após o forjamento, dois métodos distintos são considerados. No primeiro, a forma inicial do cilindro é otimizada e no outro a forma da ferramenta do primeiro estágio de conformação é otimizada. Para parametrizar a superfície livre do cilindro são utilizados diferentes métodos. Para a definição da ferramenta são também utilizados diferentes parametrizações. As estratégias de otimização propostas neste trabalho resolvem eficientemente problemas de otimização para a indústria de conformação metálica.

Estudo teórico-experimental em via de determinação de lei de atrito em escoamentos de fluidos hiperconcentrados

Fundação de Amparo à Pesquisa do Estado de São Paulo (FAPESP)

Slip complexity in earthquake fault models.

We summarize studies of earthquake fault models that give rise to slip complexities like those in natural earthquakes. For models of smooth faults between elastically deformable continua, it is critical that the friction laws involve a characteristic distance for slip weakening or evolution of surface state. That results in a finite nucleation size, or coherent slip patch size, h*. Models of smooth faults, using numerical cell size properly small compared to h*, show periodic response or complex and apparently chaotic histories of large events but have not been found to show small event complexity like the self-similar (power law) Gutenberg-Richter frequency-size statistics. This conclusion is supported in the present paper by fully inertial elastodynamic modeling of earthquake sequences. In contrast, some models of locally heterogeneous faults with quasi-independent fault segments, represented approximately by simulations with cell size larger than h* so that the model becomes "inherently discrete," do show small event complexity of the Gutenberg-Richter type. Models based on classical friction laws without a weakening length scale or for which the numerical procedure imposes an abrupt strength drop at the onset of slip have h* = 0 and hence always fall into the inherently discrete class. We suggest that the small-event complexity that some such models show will not survive regularization of the constitutive description, by inclusion of an appropriate length scale leading to a finite h*, and a corresponding reduction of numerical grid size.

Slip complexity in dynamic models of earthquake faults.

We summarize recent evidence that models of earthquake faults with dynamically unstable friction laws but no externally imposed heterogeneities can exhibit slip complexity. Two models are described here. The first is a one-dimensional model with velocity-weakening stick-slip friction; the second is a two-dimensional elastodynamic model with slip-weakening friction. Both exhibit small-event complexity and chaotic sequences of large characteristic events. The large events in both models are composed of Heaton pulses. We argue that the key ingredients of these models are reasonably accurate representations of the properties of real faults.

Finite element analysis of fault bend influence on stick-slip instability along an intra-plate fault

Earthquakes have been recognized as resulting from stick-slip frictional instabilities along the faults between deformable rocks. A three-dimensional finite-element code for modeling the nonlinear frictional contact behaviors between deformable bodies with the node-to-point contact element strategy has been developed and applied here to investigate the fault geometry influence on the nucleation and development process of the stick-slip instability along an intra-plate fault through a typical fault bend model, which has a pre-cut fault that is artificially bent by an angle of 5.6degrees at the fault center. The numerical results demonstrate that the geometry of the fault significantly affects nucleation, termination and restart of the stick-slip instability along the intra-plate fault, and all these instability phenomena can be well simulated using the current finite-element algorithm.

Strength of the Iberian intraplate lithosphere: Cenozoic deformations and seismicity

Previous studies about the strength of the lithosphere in the Iberia centre fail to resolve the depth of earthquakes because of the rheological uncertainties. Therefore, new contributions are considered (the crustal structure from a density model) and several parameters (tectonic regime, mantle rheology, strain rate) are checked in this paper to properly examine the role of lithospheric strength in the intraplate seismicity and the Cenozoic evolution. The strength distribution with depth, the integrated strength, the effective elastic thickness and the seismogenic thickness have been calculated by a finite element modelling of the lithosphere across the Central System mountain range and the bordering Duero and Madrid sedimentary basins. Only a dry mantle under strike-slip/extension and a strain rate of 10-15 s-1, or under extension and 10-16 s-1, causes a strong lithosphere. The integrated strength and the elastic thickness are lower in the mountain chain than in the basins. These anisotropies have been maintained since the Cenozoic and determine the mountain uplift and the biharmonic folding of the Iberian lithosphere during the Alpine deformations. The seismogenic thickness bounds the seismic activity in the upper–middle crust, and the decreasing crustal strength from the Duero Basin towards the Madrid Basin is related to a parallel increase in Plio–Quaternary deformations and seismicity. However, elasto–plastic modelling shows that current African–Eurasian convergence is resolved elastically or ductilely, which accounts for the low seismicity recorded in this region.

Determination of skin friction in strong pressure-gradient equilibrium and near-equilibrium turbulent boundary layers

The conventional Clauser-chart method for determination of local skin friction in zero or weak pressure-gradient turbulent boundary layer flows fails entirely in strong pressure-gradient situations. This failure occurs due to the large departure of the mean velocity profile from the universal logarithmic law upon which the conventional Clauser-chart method is based. It is possible to extend this method,even for strong pressure-gradient situations involving equilibrium or near-equilibrium turbulent boundary layers by making use of the so-called non-universal logarithmic laws. These non-universal log laws depend on the local strength of the pressure gradient and may be regarded as perturbations of the universal log law.The present paper shows that the modified Clauser-chart method, so developed, yields quit satisfactory results in terms of estimation of local skin friction in strongly accelerated or retarded equilibrium and near-equilibrium turbulent boundary layers that are not very close to relaminarization or separation.

Collective behavior of asperities as a model for friction and adhesion

Understanding friction and adhesion in static and sliding contact of surfaces is important in numerous physical phenomena and technological applications. Most surfaces are rough at the microscale, and thus the real area of contact is only a fraction of the nominal area. The macroscopic frictional and adhesive response is determined by the collective behavior of the population of evolving and interacting microscopic contacts. This collective behavior can be very different from the behavior of individual contacts. It is thus important to understand how the macroscopic response emerges from the microscopic one. In this thesis, we develop a theoretical and computational framework to study the collective behavior. Our philosophy is to assume a simple behavior of a single asperity and study the collective response of an ensemble. Our work bridges the existing well-developed studies of single asperities with phenomenological laws that describe macroscopic rate-and-state behavior of frictional interfaces. We find that many aspects of the macroscopic behavior are robust with respect to the microscopic response. This explains why qualitatively similar frictional features are seen for a diverse range of materials. We first show that the collective response of an ensemble of one-dimensional independent viscoelastic elements interacting through a mean field reproduces many qualitative features of static and sliding friction evolution. The resulting macroscopic behavior is different from the microscopic one: for example, even if each contact is velocity-strengthening, the macroscopic behavior can be velocity-weakening. The framework is then extended to incorporate three-dimensional rough surfaces, long- range elastic interactions between contacts, and time-dependent material behaviors such as viscoelasticity and viscoplasticity. Interestingly, the mean field behavior dominates and the elastic interactions, though important from a quantitative perspective, do not change the qualitative macroscopic response. Finally, we examine the effect of adhesion on the frictional response as well as develop a force threshold model for adhesion and mode I interfacial cracks.