Modified on
05 Feb 2021 01:42 pm
Skill-Lync
When designing an automobile or mechanical component, engineers pay a lot of attention to the type of material that they select. Depending largely on the forces the component frequently experiences, a range of materials are chosen and after testing each material, the best fit is determined. With the rise of computational engineering, materials are first tested in simulations before they are tested using prototypes. In this project, we will be designing a component and simulate the impact on it to understand how the material reacts during collision.
The objective of this project is to analyze the failure behavior of the plate along with the failure card. We used the Johnson-Cook Elasto-Plastic material model (Law-2) in this project. Upon simulating the collision, we will study how the material fails under stress.
Before proceeding with the simulation, we will set up the punch and the plate. The punch is designed with a mass of 5 gms. It is made to impact the plate by defining an Imposed Velocity card. The Imposed Velocity refers to the velocity with which the punch moves towards the plate.
Punch and plate setup
Imposed Velocity Card
A failure card is used to define the failure criteria for the components. The failure card without the crack formulation is defined in the CASE-1 and the failure card along with the crack is defined in CASE-2. This helps in understanding which setting gives more realistic results. When the elements exceed the failure criteria mentioned, they get deleted. We will compare the behavior of each material with and without a failure card.
The model has both the Johnson failure card as well as EPS_p_max value, with XFEM value as 0.
Xfem = 0
EPS_p_max = 0.151.
Ifail_sh = 2
When the stress and strain levels reach 15% of plastic strain, the elements fail.
For Shell elements, in each integration point, the stress in the layer is set to zero. When the stress reaches the last layer, the elements get deleted.
The model has both the Johnson failure card as well as EPS_p_max value, with XFEM value as 1.
Xfem = 1
EPS_p_max = 0.151.
Ifail_sh = 1
When the stress and strain level reaches 15% of plastic strain, the elements fail.
For shell elements, when the stress reaches the one integration point, the elements get deleted.
The Elastic-Plastic Strain (EPS_max) is used to define the failure criteria for the material. Here in CASE-3, the EPS_max value is defined and in CASE-4, the EPS_max value is not defined.
EPS_p_max = 0.151.
The model has only EPS_p_max value and no Johnson failure card. So, the elements fail and get deleted when stress causes 15% of plastic strain.
The model has no EPS_p_max value and Johnson failure card.
The material we will be testing is LAW – 2 (Elasto-Plastic Material). The properties of the card are as follows:
Initial density (rho) = 0.0028 g/mm3
Young’s Modulus (E) = 71000MPa
Poisson’s Ratio (nu) = 0.33
True yield stress (a) = 290MPa
Hardening Modulus(b) = 562.3
Hardening exponent (n) = 0.63
Maximum plastic strain for failure (EPS_p_max) = 0.151
Maximum stress (sig_max0) or UTS = 425MPa
We observed the behavior of the material in 4 different cases:
1.The elements are DELETED(CASE-1) 2.The elements are CRACKED(CASE-2)
From the above images of CASE-1 & CASE-2, the deletion and the cracking of the element is seen clearly.
CASE-3 CASE-4
Thus, we were able to analyze the failure behavior of a material in different cases. Considering the performance of the material during the collision, this material is suitable for real-life scenarios. We can employ the same procedure to analyze the failure behavior of other materials such as brittle plastic, elastic material, etc., and decide on the best material for a particular piece of equipment.
Author
SarangarajanV
Author
Skill-Lync
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