Simulation of crack propagation based on eigenerosion in brittle and ductile materials subject to finite strains

In this paper, a framework for the simulation of crack propagation in brittle and ductile materials is proposed. The framework is derived by extending the eigenerosion approach of Pandolfi and Ortiz (Int J Numer Methods Eng 92(8):694–714, 2012. 10.1002/nme.4352) to finite strains and by connecting it with a generalized energy-based, Griffith-type failure criterion for ductile fracture. To model the elasto-plastic response, a classical finite strain formulation is extended by viscous regularization to account for the shear band localization prior to fracture. The compression–tension asymmetry, which becomes particularly important during crack propagation under cyclic loading, is incorporated by splitting the strain energy density into a tensile and compression part. In a comparative study based on benchmark problems, it is shown that the unified approach is indeed able to represent brittle and ductile fracture at finite strains and to ensure converging, mesh-independent solutions. Furthermore, the proposed approach is analyzed for cyclic loading, and it is shown that classical Wöhler curves can be represented.

Particle-Based Numerical Simulation Study of Solid Particle Erosion of Ductile Materials Leading to an Erosion Model, Including the Particle Shape Effect

Solid particle erosion inevitably occurs if a gas–solid or liquid–solid mixture is in contact with a surface, e.g., in pneumatic conveyors. Having a good understanding of this complex phenomenon enables one to reduce the maintenance costs in several industrial applications by designing components that have longer lifetimes. In this paper, we propose a methodology to numerically investigate erosion behavior of ductile materials. We employ smoothed particle hydrodynamics that can easily deal with large deformations and fractures as a truly meshless method. In addition, a new contact model was developed in order to robustly handle contacts around sharp corners of the solid particles. The numerical predictions of erosion are compared with experiments for stainless steel AISI 304, showing that we are able to properly predict the erosion behavior as a function of impact angle. We present a powerful tool to conveniently study the effect of important parameters, such as solid particle shapes, which are not simple to study in experiments. Using the methodology, we study the effect of a solid particle shape and conclude that, in addition to angularity, aspect ratio also plays an important role by increasing the probability of the solid particles to rotate after impact. Finally, we are able to extend a widely used erosion model by a term that considers a solid particle shape.

The Mechanical Properties and Elastic Anisotropy of η’-Cu6Sn5 and Cu3Sn Intermetallic Compounds

Full intermetallic compound (IMC) solder joints present fascinating advantages in high-temperature applications. In this study, the mechanical properties and elastic anisotropy of η’-Cu6Sn5 and Cu3Sn intermetallic compounds were investigated using first-principles calculations. The values of single-crystal elastic constants, the elastic (E), shear (G), and bulk (B) moduli, and Poisson’s ratio (ν) were identified. In addition, the two values of G/B and ν indicated that the two IMCs were ductile materials. The elastic anisotropy of η’-Cu6Sn5 was found to be higher than Cu3Sn by calculating the universal anisotropic index. Furthermore, an interesting discovery was that the above two types of monocrystalline IMC exhibited mechanical anisotropic behavior. Specifically, the anisotropic degree of E and B complied with the following relationship: η’-Cu6Sn5 > Cu3Sn; however, the relationship was Cu3Sn > η’-Cu6Sn5 for the G. It is noted that the anisotropic degree of E and G was similar for the two IMCs. In addition, the anisotropy of the B was higher than the G and E, respectively, for η’-Cu6Sn5; however, in the case of Cu3Sn, the anisotropic degree of B, G, and E was similar.

Assessment of the Hardening Behavior and Tensile Properties of a Cold-Rolled Bainitic–Ferritic Steel

The automotive field is continuously researching safer, high-strength, ductile materials. Nowadays, dual-phase (DP) steels are gaining importance, since they meet all these requirements. Dual-phase steel made of ferrite and bainite is the object of a complete microstructural and mechanical characterization, which includes tensile and bending tests. This specific steel contains ferrite and bainite in equal parts; ferrite is the soft phase while bainite acts as a dispersed reinforcing system. This peculiar microstructure, together with fine dispersed carbides, an extremely low carbon content (0.09 wt %), and a minimal degree of strain hardening (less than 10%) allow this steel to compete with traditional medium-carbon single-phase steels. In this work, a full pearlitic C67 steel containing 0.67% carbon was used as a benchmark to build a comparative study between the DP and SP steels. Moreover, the Crussard–Jaoul (C-J) and Voce analysis were adopted to describe the hardening behavior of the two materials. Using the C-J analysis, it is possible to separately analyze the ferrite and bainite strain hardening and understand which alterations occur to DP steel after being cold rolled. On the other hand, the Voce equation was used to evaluate the dislocation density evolution as a function of the material state.

Retreatment of Polymer Wastes by Disintegrator Milling

Global introduction of waste utilization techniques to the polymer market is currently not fully developed but has enormous potential. Before reintegration of used material into a new product, it normally requires grinding, that is shredding, crushing, or milling. In traditional grinders, the generated stresses in the material to be ground are equal to or less than the strength of the material. If by traditional methods, the stresses generated are compressive + shift, so by milling based on collision are tension + shift. Due to the high stress-material strength ratio at collision, it is possible to crush not only brittle materials but also ductile materials. This process allows easily combining the grinding of composite materials with their separation into individual constituents. In the current study, the mechanical recycling of the following groups of polymer materials was studied: pure brittle and soft polymers (PMMA, HDPE and IER), blends of plastics (ABS+PMMA, PC + ABS), reinforced plastics (PMMA+GFP); elastomers (rubber and tyres), and printed circuit boards (PCB).

Actuator and Process Development for Vibration Assisted Turning of Steel

Due to continuous tool engagement, turning processes tend to form long chips when machining ductile materials. These chip shapes have a negative influence on process performance and productivity. One approach to improve chip breakage is superimposition of vibrations in feed direction of the turning process, which leads to a modulation of uncut chip thickness. In a joint industrial project with Schaeffler Technologies AG & Co. KG, Fraunhofer IWU developed an oscillating actuator for turning. The actuator converts a rotational movement of a drive motor into a translational vibration via an eccentric gear. The tool shank is mounted in solid joint assemblies. With this prototypical system, a cyclic movement of the tool in feed direction can be realized. The typical operating parameters of the actuator is within the range of 1...100 Hz with adjustable vibration amplitudes up to 0.6 mm peak-to-peak. A significant improvement in chip breaking during the machining of steel 1.0503 was shown in cutting tests.

Mechanical competition alters the cellular interpretation of an endogenous genetic program

The intrinsic genetic program of a cell is not sufficient to explain all of the cell’s activities. External mechanical stimuli are increasingly recognized as determinants of cell behavior. In the epithelial folding event that constitutes the beginning of gastrulation in Drosophila, the genetic program of the future mesoderm leads to the establishment of a contractile actomyosin network that triggers apical constriction of cells and thereby tissue folding. However, some cells do not constrict but instead stretch, even though they share the same genetic program as their constricting neighbors. We show here that tissue-wide interactions force these cells to expand even when an otherwise sufficient amount of apical, active actomyosin is present. Models based on contractile forces and linear stress–strain responses do not reproduce experimental observations, but simulations in which cells behave as ductile materials with nonlinear mechanical properties do. Our models show that this behavior is a general emergent property of actomyosin networks in a supracellular context, in accordance with our experimental observations of actin reorganization within stretching cells.