Upload
darleen-russell
View
222
Download
4
Tags:
Embed Size (px)
Citation preview
Dr. Mark HorstemeyerCAVS Chair Professor
ASME FellowMississippi State [email protected]
662.325.5449
Multiscale Modeling:An Overview
Outline1) Modeling Philosophy Overview2) MSU Internal State Variable Plasticity-Damage Model (MSU DMG 1.0) Theory
1) Horstemeyer, M.F., Lathrop, J., Gokhale, A.M., and Dighe, M., “Modeling Stress State Dependent Damage Evolution in a Cast Al-Si-Mg Aluminum Alloy,” Theoretical and Applied Fracture Mechanics, Vol. 33, pp. 31-47, 2000
2) Bammann, D. J., Chiesa, M. L., Horstemeyer, M. F., Weingarten, L. I., "Failure in Ductile Materials Using Finite Element Methods," Structural Crashworthiness and Failure, eds. T. Wierzbicki and N. Jones, Elsevier Applied Science, The Universities Press (Belfast) Ltd, 1993.
3) Image Analysis Tool 1.0 User’s Tutorial4) DMGfit 1.0 User’s Tutorial5) MSU MultiStage Fatigue Model (MSU MSF 1.0) Theory
1) McDowell, D.L., Gall, K., Horstemeyer, M.F., and Fan, J., “Microstructure-Based Fatigue Modeling of Cast A356-T6 Alloy,” Engineering Fracture Mechanics, Vol. 70, pp.49-80, 2003.
6) MSFfit 1.0 User’s Tutorial7) MSU ISV Thermoplastic Model (MSU TP 1.0) Theory
1) J.L. Bouvard, D.K. Ward, D. Hossain, E.B. Marin, D.J. Bammann, and M.F. Horstemeyer, “A General Inelastic Internal State Variable Model for Amorphous Glassy Polymers,” submitted to Acta Mechanica
8) TPfit 1.0 User’s Tutorial
Computational Manufacturing and Design
Mission: We couple multidisciplinary research of solid mechanics, materials, physics, and applied mathematics in three synergistic areas: theoretical modeling, experimentation, and large scale parallel computational simulation to optimize design and manufacturing processes.
Macroscale ISV Continuum
Bridge 1 = Interfacial Energy, Elasticity
Atomistics(EAM,MEAM,MD,MS,
NmBridge 2 = Mobility
Bridge 3 = Hardening Rules
Bridge 4 = Particle Interactions
Bridge 5 = Particle-Void Interactions
Void \ Crack Interactions
Bridge 11 = FEA
ISV
Bridge 12 = FEA
DislocationDynamics (Micro-3D)
100’s Nm
ElectronicsPrinciples (DFT)
Å
Crystal Plasticity(ISV + FEA)10-100 µm
Crystal Plasticity(ISV + FEA)µm
CrystalPlasticity
(ISV + FEA)100-500µm
Bridge 6 =Elastic Moduli
Bridge 7 =High Rate
Mechanisms
Bridge 8 =Dislocation
Motion
Bridge 9 =Void \ Crack Nucleation
Bridge 10 =Void \ Crack
Growth
Macroscale ISV Continuum
Multiscale Modeling
IVS ModelVoid Growth
Void/Void CoalescenceVoid/Particle Coalescence
Fem AnalysisIdealized Geometry
Realistic RVE GeometryMonotonic/Cyclic Loads
Crystal Plasticity
ExperimentFracture of SiliconGrowth of Holes
ExperimentUniaxial/torsionNotch Tensile
Fatigue Crack GrowthCyclic Plasticity
FEM AnalysisTorsion/Comp
TensionMonotonic/Cyclic
Continuum ModelCyclic Plasticity
Damage
Structural Scale
Experiments FEM
ModelCohesive Energy
Critical Stress
AnalysisFracture
Interface Debonding
Nanoscale
ExperimentSEM
Optical methods
ISV ModelVoid Nucleation
FEM AnalysisIdealized GeometryRealistic Geometry
Microscale
Mesoscale
Macroscale
ISV ModelVoid Growth
Void/Crack Nucleation
ExperimentTEM
Multiscale Experiments1. Exploratory exps2. Model correlation exps3. Model validation exps
OptimalProductProcess
Environment(loads, boundary
conditions)
Product(material, shape,
topology)
Process(method, settings,
tooling)
Design Options
Cost Analysis
Model
FEM Analysis
Experiment
Multiscales
Analysis Product & Process
Performance(strength, reliability,
weight, cost, manufactur-ability
)
Design Objective & Constraints
Preference & Risk
Attitude
Optimization under Uncertainty
Design Optimization
Engineering tools (CAD, CAE, etc.)
Conceptual design process(user-friendly interfaces)
IT technologies(hidden from the engineer)
CyberInfrastructure
D
CB
A
E
Standard FEAStress
(from highest to lowest)
DAC E B
Inclusion (from most severe
to less severe)BEADC
Damage (from most severe
to less severe)ADECB
initial failure site
(a)
(b)
Region 3Region 1model
experiment
0
10000
20000
30000
40000
50000
60000
70000
80000
0 5 10 15 20 25
app
lied
load
(N
ewto
ns)
applied displacement (mm)
before CRADA workpeak design load =48000 N
after CRADA workpeak design load=72000 N
15000
20000
25000
30000
35000
40000
10 100 1000 104 105
app
lied
lo
ad (
New
ton
s)
cycles
after CRADA work
before CRADA work
Result: To optimize a redesign such that 25% weight saved
50% increase in load-bearing capacity100% increase in fatigue life
$2 less per part
GM CADILLAC CONTROL ARM LIGHTWEIGHT DESIGN
(2000)Objective: To employ multiscale material modeling
to reduce the weight of components
Truth!Wrong!
System
Subsystem
Component
Internal State Variable Plasticity-Damage
Simulation
StructuresPore sizeNearest Neighbor DistanceDendrite Cell SizePorosity
Boundary ConditionsPanic brakePothole strikeForcesMoments
GM Corvette Cradle Magnesium Design (2005)
ED
BA
C
F Mises Stress
Initial Porosity
Damage
Highest D C EB F BE E DA D AF B F
Lowest C A C
Cradle Load-to-Failure Simulation Results
Modern FEA answer
Modern Materials Science answer True answer
Powder Metal FC0205 Steel (2008)Compaction, Sintering, and Performance
failure predicted by damage model under performance with distribution of initial porosity
experiment
model
maximum von Mises Stress
Note: standard FEA wouldhave given the wrong location
I – Compaction Modeling (Validation)Main Bearing Cap – Green Density Distribution- after Springback (g/cc)
FEA ModelGeometry and Material Solution imported from ABAQUS/ Explicit to
ABAQUS/Standard for Elastic Springback Analysis
ExperimentX-ray CT
2D X-Ray CT
FEA 205Q
Image Analysis
9
1 32
4
57 8
10
11
6
1213
1615
1718
14
19 20
1 32
4
57 8
10
11
6
1213
1615
1718
14
19 20
9
Density Immersion
Density (g/cc)
+7.00
+6.90+6.85+6.80+6.75+6.70+6.65+6.60+6.55
+6.95
+6.50+6.45+6.40
+7.05
ExperimentImmersion and Image Analysis Densities
by Zone
Volume grows 0.6%after springback
density
Cyberinfrastructure Design FrameworkFEAsimulation
Optimization
CAD
Model calibration
Materialpropertiesrepository
Inputdeck
Material
Geometry
FEAoutputs
FEA setup
Validation
Computeplatformsettings
Material models andconstants
Mesh
Boundaryconditions/loading
Post-processingdirectives
Design objectives/requirements
Experimentaldata
MSF
MSU Multiscale Modeling
• Vision: In 5-10 years, we are internationally recognized as the premiere material modeling group in world for our validated and verified research and production models
• Mission: systemize our multiscale modeling capability so that the cyberinfrastructure easily admits each different aspect of the modeling characteristics (codes, materials info, mechanical properties tests, multiscale models, etc)
Modeling History and Overview• Started in thermonuclear weapons design at Sandia
(no underground systems level testing)• Populate the space of systems levels with simulations
(simulation based design and multiscale modeling to get correct physics)
• Used for many different metal alloys in materials processing and life-performance analysis
• Tech transfer to Navy, Army, and automotive applications
• Notion of history modeling with internal state variables
FEA Simulations and Timeline Using Internal State Variable Model
• Early 1980’s: steel alloys for weapon laydown event (highlight: front cover of Science) plasticity, damage, and fracture
• Mid 1980’s-1990’s: forging process: rex• Late 1980’s: analysis of various components:
plasticity and failure• Early 1990’s: Navy submarines lethality, welding• Mid 1990’s: forming, extrusion, heat treatment• Late 1990’s: automotive castings• Early 2000’s: everything automotive• Mid 2000’s: Army vehicle component designs• Late 2000’s: polymers and powder metals
Metals Modeled by Macroscale DMG ISV Plasticity-Damage Model 1.0
• Steel Alloys (15)– A286, AF, C1008, S7tool, 1020, 10b22, 4140, 4340, 210SS, 304LSS, 319SS,
HY80, HY100, HY130, FC0205• Aluminum Alloys(16)
– 1100, 2024T0, 2024T35, 2024T4, 5083, 5086, 6061T0, 6022, 6050, 6061T0, 6061T6, 7039, 7075T0, 7075T6, A319, A356
• Magnesium Alloys (7)– AM20, AM30, AM50, AM60, AZ31, AZ91, AE44
• Titanium Alloys (4)– Ti7Al4Mo, Ti8Al1Mo1V, Ti0Al6V4, Ti6Al6V2Sn
• Uranium Alloys (2)– D38, D380075Ti
• Nickel (2)– 99.99% pure, In718
• Brass (1)– 99% pure
70 metal alloys to date!
Phenomena N=Model 1
Phenomena 1=Model 1
Phenomena 2=Model 2
Phenomena 3=Model 3
Phenomena N=Model N
.
.
.
.
Classical Modeling Paradigm MSU CAVS Modeling Paradigm
MSU CAVS CMD Material Modeling Philosophy
Phenomena 1=Model 1
Phenomena 2=Model 1+few additional constants
Phenomena 3=Model 1+few additional constants
.
.
.
.
.
Note: with every new phenomena the modelmoves back to a general abstraction so if the newconstants are zero the original model results
Note: with each new model, many moreconstants are introduced with the newmodel
Phenomena N=Model 1
Creep=Nabarro-Herring Model
Plasticity=Ramberg-Osgood
Damage=Johnson-Cook
Phenomena N=Model N
.
.
.
.
Classical Modeling Paradigm MSU CAVS Modeling Paradigm
Example of Philosophies with Creep and Plasticity
Creep=Garafalo flow rule
Plasticity=Garafalo + dislocation density ISVs
Damage=Garafalo+disl ISVs+Damage ISVs
.
.
.
.
.
Note: with every new phenomena the modelmoves back to a general abstraction so if the newconstants are zero the original model results
Note: with each new model, many moreconstants are introduced with the addednew model
Macroscale Research and Production ModelsNote 1: Production models/codes must have a documented citable journal article for each version of the code
a. makes impact factor greaterb. makes it easier for next graduate student to add incremental improvements
Note 2: Production models/codes must build on the previous worka. helps systemize and synergize our efforts in terms of research and fundingb. clears up confusion to outsider customers and industryc. helps user base
Note 3: Production models/codes must have a theoretical and user’s manuala. absolute necessity for new graduate students and new user’sb. helps the broad usage of the model over timec. this alone may lead the greatest impact over time
Note 4: Only a Production model/code can go into the cyberinfrastructure
Journal Article History and MSU CAVS R&D Modeling Plan
Bammann (1990) temperature and strain rate dependent unified-creep plasticity model (Bammann Model)
Bammann et al. (1993) applications of Bammann model with damage (no formal name)BCJ (1995) formalization of model (really mod of 1993 paper: BCJ)Horstemeyer et al. (2000) microstructure with damage (DMG model)
MSU CAVS DMG ISV Model 1.0
Version 1.1
ProductionResearch
EMMI
AnisotropicDamage (Solanki)
PressureDep yield(Hammi)
Coalescence(Allison,Oglesby)
Version 1.2
Version 1.3
Elastic moddamage(Allison)
Version 1.4
Recrystallization/grain growth
?
Add more materials with quantifying the structure-property relations
V&V
V&V
MSU CAVS R&D Modeling Plan (cont)
MSU CAVS DMG ISV Model 1.0
Version 1.5
ProductionResearch
EMMI
Plastic spin(Najafi)
High rateStress stateDep(Tucker)
Version 1.6
Version 1.7
Hardeningchange(Bammann)
Version 2.0 (new setof constants required
for all materials)
Twinning(Oppedal,Bammann,Horstemeyer,Marin)
Version 1.8
Subscalestudies
V&V
MSU CAVS R&D Modeling Plan (cont)
MSU CAVS ND DMG ISV Model 2.0
Version 2.1
ProductionResearch
Phase Transform(LWang)
Nonlocaldamage(Solanki)
Version 2.2
Version 2.3
PPT morphology(El Kadiri)
Solidification(Felicelli,LWang)
New name??
Subscalestudies
Validation and Verification (V&V)
Research FE CodesTahoeRamaswamy code (nonlocal damage, implicit)Winters code (coupled thermomechanical)ABAQUS
Production FE CodesABAQUSLS DynaESI PamcrashESI PamstampMD Nastran
model Fitting algorithm(Carino)
Modelverification
Model implementation
Metals Modeled by MultiStage Fatigue Model 1.0
• Steel Alloys (3)– 4140, 319SS, FC0205
• Aluminum Alloys(5)– 2024T0, 7075T6, A319, A356, A380
• Magnesium Alloys (7)– AM30, AM50, AM60, AZ31, AZ61, AZ91, AE44
15 metal alloys to date!
Polymers Modeled by MultiStage Fatigue Model 1.0• Polyurethane (2)
– Pure, carbon nanotube polyurethane• Elastomer (2)
– SBR, track rubber• Polycarbonate (1)
Journal Article History and MSU CAVS R&D Modeling Plan
McDowell et al (2003) microstructure-sensitive MultiStage Fatigue (MSF)Xue et al (2007) grain size and texture effectsJordon et al (2008) nearest neighbor distance and elastic moduli effect on porosity
MSU CAVS MSF Model 1.0
Version 1.1
ProductionResearch
Thermomechanical(???)
SymptoticExpansionsISVs (???)
Corrosion(???)
Version 1.2
Version 1.3
Polymers(Bouvard,Brown)
Version 1.4
Add more materials with quantifying the structure-property relations
V&V
Polymers Modeled by Macroscale ISV ViscoElastic-ViscoPlasticity-Damage Model 1.0
• Polycarbonate (1)• Polypropylene (1)• Polyurethane (1)• ABS• Elastomer (3-Santoprene, natural rubber, SBR)• Nylon (4)
– Nylon 6.6, Nylon 4.4, E-glass+Nylon, S-glass+Nylon• Kevlar• Brain• Liver• Tendon• Placenta
12 polymers to date!
Journal Article History and ISV Polymer Modeling Plan
Bammann (1990) temperature and strain rate dependent unified-creep plasticity modelBammann et al. (1993) applications of Bammann model with damageBCJ (1995) formalization of modelHorstemeyer et al. (2000) microstructure with damage
MSU CAVS Poly DMG ISV Model 1.0
Version 1.1
ProductionResearch
viscoelasticity(Prabhu)
?Add more materials with quantifying the structure-property relations
V&V
Boyce-ArrudaAnand
rubbers(Brown) Version 1.2
nanocomposites(Lacy, Shi, Zhang,Pittman, Toghiani)
Version 1.3
Model calibration tools developmentCMD Theoreticians
RLCarino
THaupt/CCG
Model evaluationroutine(Fortran, MATLAB)
Computationalbackendfor model(MATLAB)
DMG
ImageAnalyzer
MSF
BB->VEP
EMMI
PQplot
MSC
Piecewise lines->DSR
DMG UMAT+Uncertainty
DMG VUMAT+Nucleation data
VPSC
MSF+amplitude loading
(Fung->Biomaterial?)
Dislocation ANN GUI
ImageStitcher
RPTpostprocessorStand-aloneexecutable
Webservice
Tool & Status
Web-based
Users
PC-based
Feedback
Production codes
Model code, Providers, UsersDMG
ImageAnalyzer
MSF
BB->VEP
EMMI
PQplot
MSC
Piecewise curves->DSR
DMG UMAT+Uncertainty
DMG VUMAT+Nucl. data
VPSC
MSF+amplitude loading
(Fung->Biomaterial?)
Dislocation ANN GUI
ImageStitcher
RPTpostprocessor
mfhorst
tnw7
mfhorst, bjordan
jeanluc
ebmarin
yhammi
yhammi
(jeanluc)
kns3
kns3
aoppedal, haitham
Mfhorst,bjordan
(lwilliams)
ElKadiri
(bjordon)
(axue)
(various), S.Agnew, Y.Guo
(various)
yhammi, bjordon, paul, adrian
jeanluc, jef83
jcrapps
(USAMP-PM?)
(USAMP-PM?)
sponder
kns3
kns3
aoppedal
(NGC?)
?
osama, (haitham’s student)
(axue’s student)
Production codes
Computational Manufacturing and Design
Mission: We couple multidisciplinary research of solid mechanics, materials, physics, and applied mathematics in three synergistic areas: theoretical modeling, experimentation, and large scale parallel computational simulation to optimize design and manufacturing processes.