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In this paper, the J-integral is derived for temperature-dependent elastic–plastic materials described by incremental plasticity. It is implemented using the equivalent domain integral method for assessment of three-dimensional cracks based on results of finite-element calculations. The J-integral considers contributions from inhomogeneous temperature fields and temperature-dependent elastic and plastic material properties as well as from gradients in the plastic strains and the hardening variables. Different energy densities are considered, the Helmholtz free energy and the stress-working density, providing a physical meaning of the J-integral as a fracture criteria for crack growth. Results obtained for a plate with two different crack configurations each loaded by a cool-down thermal shock show domain-independence of the incremental J-integral for different energy densities even for high temperature gradients and significant temperature-dependence of the yield stress and the hardening exponent in the presence of large scale yielding. Hence, the derived J-integral is an appropriate parameter for the assessment of cracks in thermomechanically loaded components.
Turbocharger housings in internal combustion engines are subjected to severe mechanical and thermal cyclic loads throughout their life-time or during engine testing. The combination of thermal transients and mechanical load cycling results in a complex evolution of damage, leading to thermo-mechanical fatigue (TMF) of the material. For the computational TMF life assessment of high temperature components, the DTMF model can provide reliable TMF life predictions. The model is based on a short fatigue crack growth law and uses local finite-element (FE) results to predict the number of cycles to failure for a technical crack. In engine applications, it is nowadays often acceptable to have short cracks as long as they do not propagate and cause loss of function of the component. Thus, it is necessary to predict not only potential crack locations and the corresponding number of cycles for a technical crack, but also to determine subsequent crack growth or even a possible crack arrest. In this work, a method is proposed that allows the simulation of TMF crack growth in high temperature components using FE simulations and non-linear fracture mechanics (NLFM).
A NLFM based crack growth simulation method is described. This method starts with the FE analysis of a component. In this paper, the method is demonstrated for an automotive turbocharger housing subjected to TMF loading. A transient elastic-viscoplastic FE analysis is used to simulate four heating and cooling cycles of an engine test. The stresses, inelastic strains, and temperature histories from the FEA are then used to perform TMF life predictions using the standard DTMF model. The crack position and the crack plane of critical hotspots are then identified. Simulated cracks are inserted at the hotspots. For the model demonstrated, cracks were inserted at two hotspot locations. The ΔJ integral is computed as a fracture mechanics parameter at each point along the crack-front, and the crack extension of each point is then evaluated, allowing the crack to grow iteratively. The paper concludes with a comparison of the crack growth curves for both hotspots with experimental results.
Für langfaserverstärkte Thermoplaste (LFT) wird ein repräsentatives Volumenelement (RVE) für FEM-Simulationen generiert. Dies geschieht unter Berücksichtigung von mikrostrukturellen Kenngrößen wie Faserorientierungsverteilung, -volumengehalt und -längenverteilung, die für einen charakteristischen Werkstoffzustand experimentell ermittelt wurden. Mittels Mikrostruktursimulationen wird das Kriechverhalten von LFT untersucht. Das viskoelastische Verhalten der Matrix wird experimentell an Substanzproben aus Polypropylen ermittelt und in die RVE-Simulationen mit einem modifizierten Burgers-Modell implementiert. Schließlich werden die Rechnungen mit verschiedenen, fiktiven sowie experimentell ermittelten Faserlängenverteilungen mit Kriechversuchen am LFT verglichen. Es zeigt sich eine starke Abhängigkeit des Kriechverhaltens von der Faserlänge und eine hohe Prognosegüte der Simulationen, die die experimentell ermittelte Längenverteilung berücksichtigen.
Cast aluminum cylinder blocks are frequently used in gasoline and diesel internal combustion engines because of their light-weight advantage. However, the disadvantage of aluminum alloys is their relatively low strength and fatigue resistance which make aluminum blocks prone to fatigue cracking. Engine blocks must withstand a combination of low-cycle fatigue (LCF) thermal loads and high-cycle fatigue (HCF) combustion and dynamic loads. Reliable computational methods are needed that allow for accurate fatigue assessment of cylinder blocks under this combined loading. In several publications, the mechanism-based thermomechanical fatigue (TMF) damage model DTMF describing the growth of short fatigue cracks has been extended to include the effect of both LCF thermal loads and superimposed HCF loadings. This approach is applied to the finite life fatigue assessment of an aluminum cylinder block. The required material properties related to LCF are determined from uniaxial LCF tests. The additional material properties required for the assessment of superimposed HCF are obtained from the literature for similar materials. The predictions of the model agree well with engine dyno test results. Finally, some improvements to the current process are discussed.
In this paper, the effect of the polycrystalline microstructure on crack-tip opening displacement and crack closure is investigated for microstructural short plane strain fatigue cracks using the finite-element method. To this end, cracks are introduced in synthetically generated microstructures and the grain properties are described using a single crystal plasticity model with kinematic hardening. Additionally, finite-element calculations without resolved microstructure and von Mises plasticity with kinematic hardening are performed. Fully-reversed strain-controlled cyclic loadings are considered under large-scale yielding conditions as typical for low-cycle fatigue problems. The crack opening stress and the cyclic crack-tip opening displacement are significantly influenced by the local grain structure. While the stabilized crack opening stresses obtained with the microstructure-based finite-element model are in good accordance with the von Mises plasticity results, the differences in the cyclic crack opening displacement are addressed to the asymmetric plastic strain fields in the plastic wake behind the crack-tip of the microstructure-based model. The asymmetric plastic strain fields result in discontinuous and premature contact of the crack flanks.
In this paper, the influence of the material hardening behavior on plasticity-induced fatigue crack closure is investigated for strain-controlled loading and fully plastic, large-scale yielding conditions by means of the finite element method. The strain amplitude and the strain ratio are varied for given Ramberg–Osgood material properties representing materials with different hardening behavior. The results show a pronounced influence of the hardening behavior on crack closure, while no significant effect is found from the considered strain amplitude and strain ratio. The effect of the hardening behavior on the crack opening stress cannot be described by existing crack opening stress equations.
In this work, time-independent and time-dependent plasticity models are presented that are well suited for the calculation of stresses and strains with the finite-element method to assess the low-cycle and thermomechanical fatigue life of engineering components. The focus are plasticity models that are available in finite-element programs nowadays as standard material models and describe isotropic and kinematic hardening, strain-rate dependency as well as static recovery of hardening. For the presented models, aspects relevant for the application of the models are addressed as the determination of the material properties and the numerical implementation. Nevertheless, the plasticity models are also embedded in the thermodynamic framework used for the derivation of thermodynamically consistent plasticity models. Only uniaxial formulations are used to achieve a good readability and preventing the use of tensors.
Hot forging dies are subjected to high cyclic thermo-mechanical loads. In critical areas, the occurring stresses can exceed the material’s yield limit. Additionally, loading at high temperatures leads to thermal softening of the used martensitic materials. These effects can result in an early crack initiation and unexpected failure of the dies, usually described as thermo-mechanical fatigue (TMF). In previous works, a temperature-dependent cyclic plasticity model for the martensitic hot forging tool steel 1.2367 (X38CrMoV5-3) was developed and implemented in the finite element (FE)-software Abaqus. However, in the forging industry, application-specific software is usually used to ensure cost-efficient numerical process design. Therefore, a new implementation for the FE-software Simufact Forming 16.0 is presented in this work. The results are compared and validated with the original implementation by means of a numerical compression test and a cyclic simulation is calculated with Simufact Forming.