| 1. |
- Andersson, Tobias
(author)
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Mechanical Behaviour of Adhesive Layers : Methods to Extract Peel and Mixed Mode Properties
- 2006
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Doctoral thesis (other academic/artistic)abstract
- Mechanical Behaviour of Adhesive Layers Methods to Extract Peel and Mixed Mode Properties TOBIAS ANDERSSON Department of Applied Mechanics Chalmers University of Technology ABSTRACT This thesis is concerned with methods to extract material properties of thin adhesive layers loaded in peel and in mixed mode. The first part of the thesis is devoted to an experimental method to determine the complete stress-elongation relation (or cohesive law) for an adhesive layer loaded in peel using the DCB-specimen. The method is based on the concept of equilibrium of the energetic forces acting on the specimen. Two sources of energetic forces are identified: the start of the adhesive layer and the positions of the two acting loads. By use of the concept of equilibrium of energetic forces, it is possible to measure the energy release rate of the adhesive layer instantaneously during an experiment. The complete stress-elongation relation is found to be the derivative of the energy release rate with respect to the elongation of the adhesive layer at its start. By this procedure, an effective property of the adhesive layer is measured. The validity of the approach is investigated by experiments where the adherends deform 1) elastically and 2) plastically. It is found that a unique stress-elongation is obtained when the adherends deform elastically. The same relation cannot be used to predict the experiments where the adherends deform plastically indicating that the approach has limited applicability. The second part of the thesis is concerned with the development of a mesomechanical finite element model of a thin adhesive layer loaded in mixed mode. The model is calibrated to previously performed experiments. In these, the adhesive layer is loaded in monotonically increasing peel or shear. An in situ SEM-study is also performed and used to guide the modelling and calibration. The purpose of the mesomechanical finite element model is to facilitate the development of constitutive laws for adhesive layers. The modelling is based on Xu and Needleman’s method where all continuum finite-elements are surrounded by interface elements that allow for the development of micro cracks. Thus, this enables the modelling of the entire process of degradation and fracture of the adhesive layer. A genetic algorithm is developed for the calibration. The simulations are shown to be in reasonably good agreement with the experiments. Keywords: adhesive layer, stress-elongation relation, J-integral, energetic force, experimental method, RVE, interface elements, genetic algorithm
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| 2. |
- Carlberger, Thomas
(author)
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Adhesive joining for crashworthiness : material data and explicit FE-methods
- 2008
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Doctoral thesis (other academic/artistic)abstract
- Today, crash simulations replace crash testing in the product development phase in theautomotive industry. High quality simulations enable shorter product development time andhigher competitiveness. However, increasing requirements regarding emissions andcrashworthiness are demanding optimised material choice in the parts constituting the carbody structure. Lightweight materials are becoming frequently used. Joining dissimilarmaterials is difficult using common joining techniques like spot welding. To this end,adhesive joining is currently gaining popularity not only due to the ability to join dissimilarmaterials, joint integrity and structural stiffness both increase by the use of adhesive joining.Moreover, the number of spot welds may be reduced in hybrid joints.In this thesis, adhesive joints are studied with respect to crashworthiness of automotivestructures. The main task for the adhesive is not to dissipate the impact energy, but to keep thejoint integrity so that the impact energy can be consumed by plastic work of the basematerials. Fracture of adhesives can be accurately modelled by cohesive zones. The dynamicbehaviour of finite element structures containing cohesive zones is studied using a simplifiedstructure. An amplified strain rate is found in the adhesive as compared to the base material.The cohesive zone concept is used in the development of a 2D interphase element. Theaccuracy and time step influence of the interphase element is compared to solutions based oncontinuum element representation of the adhesive. The interphase element is found to predictfracture of the adhesive joint with engineering accuracy and has a small effect on the timestep of the explicit FE method.The cohesive laws for use in the material models of the adhesive have been determined usingdedicated test methods. The double cantilever beam specimen and the end notched flexurespecimen are used with inverse methods to determine cohesive laws in peel and shear,respectively. The cohesive laws are determined for varying temperature, strain rate andadhesive layer thickness. A built up bimaterial beam is designed for testing and simulation ofjoints consisting of bolts, adhesives and combinations of bolts and adhesives, i.e. hybridjoints. The model of the hybrid beam developed was found to be able to predict results fromimpact tests, quantified as maximum load and deformed shape of the beam.
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| 3. |
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| 4. |
- Gustafsson, Erik, et al.
(author)
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Structural optimization of castings by using ABAQUS and Matlab
- 2005
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In: Competent Design by Castings. - Espoo, Finland : VTT. - 9513862984 - 9513862992 ; , s. 39-52
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Conference paper (peer-reviewed)abstract
- In this work a general method for structural optimization of nonlinear structures is implemented using FE-analysis. The method utilizes the response surface methodology with polynomial surfaces and nonlinear programming. In such manner a method that is applicable for a large number of different classes of nonlinear problems is obtained. In this paper, the method is utilized to minimize weight of castings by including residual stresses from solidification. This is performed by first determine the residual stresses by a thermomechanical analysis of a metal structure that is cooled from a temperature above liquidus temperature down to room temperature. The thermomechanical analysis is uncoupled where the temperature distribution within the casting as a function of time is determined first and is later on used for residual stress calculations. These residual stresses are then included when the mechanical load is applied to the structure and the problem of minimum of weight is formulated. The structure shown in this paper is an example of a two dimensional geometry. The shape of the structures will of course affect the residual stress distribution during the optimization. The nonlinear models are then solved using ABAQUS/Standard. A set of solutions are generated by solving the model for a pre-defined set of parameters. In order to minimize the number of simulations and still achieve good surface approximations these parameters are taken to be D-optimal. The sets of solutions and parameters are in turn exported to Matlab where general quadratic response surfaces are fitted by the least square method. By utilizing these surfaces the problem of minimum of weight subjected to constraints on stresses is formulated. Finally, the nonlinear optimization problem is solved by sequential linear programming.
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| 5. |
- Gustafsson, Erik, et al.
(author)
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Structural optimization of castings by using Abaqus and Matlab
- 2005
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In: Proceedings of the Abaqus World Users' Conference.
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Conference paper (peer-reviewed)abstract
- In this work a general method for structural optimization of nonlinear structures is implemented using ABAQUS and Matlab. The method utilizes the response surface methodology with polynomial surfaces and nonlinear programming. In such manner a method that is applicable for a large number of different classes of nonlinear problems is obtained. For instance plasticity problems, thermomechanical problems and contact problems can be optimized using this strategy. In this paper, the method is utilized to minimize weight of castings by including residual stresses from solidification. This is performed by first determine the residual stresses by a thermomechanical analysis of a metal structure that is cooled down from a temperature above liquidus temperature down to room temperature. These residual stresses are then included when the problem of minimum of weight is formulated. The shape of the structure will of course affect the residual stress distribution during the optimization and the optimal shape will be different from the one obtained when residual stresses are not included in the analysis. The method is implemented by using a Python script and m-files. In such way a parameterized model can easily be treated in ABAQUS and Matlab during the optimization process. The parameterized geometry, loads, boundary conditions and mesh are first generated by the ABAQUS/CAE module. The nonlinear models are then solved using ABAQUS/Standard. A set of solutions are generated by solving the model for a pre-defined set of parameters. In order to minimize the number of simulations and still achieve good surface approximations these parameters are taken to be D-optimal. The sets of solutions and parameters are in turn exported to Matlab where general quadratic response surfaces are fitted by the least square method. By utilizing these surfaces the problem of minimum of weight subjected to constraints on stresses is formulated. Finally, the nonlinear optimization problem is solved by sequential linear programming where the linear part is solved using Matlab.
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| 6. |
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| 7. |
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| 8. |
- Hofwing, Magnus, 1982-, et al.
(author)
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Simulation of residual stresses in stamping dies
- 2008
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In: Proceedings of the IDDRG 2008 Conference. - Olofström : Industriellt utvecklingscentrum i Olofström AB. - 9789163329487 ; , s. 765-776
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Conference paper (peer-reviewed)abstract
- In the past stamping dies have in principle been designed by rules of thumb and intuition. As the sheet metals in the vehicle industry have got increased mechanical properties in recent years the demands on the stamping dies have increased. For instance increase in stiffness is desirable in order to better control spring-back. The most simple way to satisfy this new demand would be to make the stamping dies even more heavy in order to be able to handle the new sheet metals. Since there are restrictions of the weight of the stamping dies in the stamping machines and since the overhead cranes usually have reached the limit of what they can handle, this is not a desirable solution. Another approach, in order to increase the stiffness without increasing the weight is to use topology optimization. Recently in a master thesis at Volvo Car Corporation a conceptual design of a stamping die has been done by topology optimization. In that work no consideration is taken to the fact that the stamping die is casted. Casting implies that residual stresses possibly are produced during the solidification and cooling process. The residual stresses might affect the fatigue life and the risk of failure of the stamping die.In this work the residual stress state after casting is analyzed for the original stamping die as well as the optimized stamping die from the master thesis discussed above. The analyses are performed using an uncoupled approach, where one thermal analysis is followed by a quasi-static elasto-plastic analysis. The thermal analysis simulates the solidification and cooling during the casting process, while the quasi-static elasto-plastic analysis uses the temperature history, obtained from the thermal analysis, in order to build up residual stresses. The thermal analysis includes the release of latent heat. Furthermore, the material properties included in the heat equation (density, conductivity, specific heat) are given as temperature dependent properties for the mould as well as the casting. In the quasi-static elasto-plastic analysis the plasticity is described by the von Mises yield surface in combination with isotropic hardening and the mechanical properties (thermal expansion coefficient, Young's modulus, yield stress, hardening parameter, Poisson's ratio) are given as temperature dependent properties. The simulations show high levels of residual stresses.
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| 9. |
- Högberg, Jia Li
(author)
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Mixed mode loaded adhesive layers : from measurement of material data to analysis of structural behaviour
- 2007
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Doctoral thesis (other academic/artistic)abstract
- In manufacturing of multi-material products, a joining method that is able to cost-effectively assemble components made of dissimilar and similar material, with irregular geometries, is optimal. As an alternative, adhesive bonding is in-creasingly adapted by the industry, which is also used in manufacturing of multi-phase materials. In practice, adhesives are constrained to thin layers. An adhesive as a constrained layer behaves differently compared to the adhesive as a bulk material. In general, adhesive layers are loaded in peel (mode I), or in shear (mode II or III), or in a combination of peel and shear (mixed mode). This thesis deals with mixed mode loaded adhesive layers, from measurement of ma-terial data to analysis of structural behaviour. For studying of structural behaviour of adhesive joints, an integrated approach is developed. Arbitrarily end-loaded single-layer adhesive joints with arbitrary ad-herends of arbitrary length are analysed with the Beam/Adhesive layer (B/A) model. Closed-form solutions are obtained for the adhesive layer as well as for the adherends. For joints with a semi-infinite symmetric geometry, i.e. relative long joints with identical adherends loaded at one end, basic loading cases are obtained. Solutions to these basic loading cases are easy to use in designing of joints with this type of geometry. For nonlinear or general adhesive layers, a mode-dependent cohesive law is de-veloped. The normalized formulation is easy to implement in numerical simula-tions, yet, it captures the characteristics of adhesive layers. For experimental studies, this cohesive law is used to obtain the constitutive behaviour of an adhe-sive layer. The results confirm the ability and suitability of this cohesive law in modelling of adhesive layers. To obtain material data of adhesive layers, experimental methods are developed based on the J-integral. Two specimens, the Mixed mode double Cantilever Beams (MCB) specimen and the Unbalanced Double Cantilever Beams (UDCB) specimen, are designed to allow adhesive layers to be loaded in mixed mode. The MCB-specimen is implemented experimentally and the constitutive behav-iour of the tested adhesive layer is obtained.
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| 10. |
- Ireman, Peter, et al.
(author)
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Gradient theory of damage coupled to frictional contact and wear, and its numerical treatment
- 2009
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In: CMES - Computer Modeling in Engineering & Sciences. - : Tech Science Press. - 1526-1492 .- 1526-1506. ; 52:2, s. 125-158
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Journal article (peer-reviewed)abstract
- In this paper finite element approaches for fretting fatigue are proposed on the basis of a non-local model of continuum damage coupled to friction and wear. The model is formulated in the frame-work of a standard material. In a previous paper this was done in the spirit of Maugin, where an extra entropy flux is introduced in the second law in order to include the gradient of the internal variable in a proper manner. In this paper we follow instead the ideas of Frémond and others, where this extra entropy flux is no longer needed, but instead new non-classical balance laws associated to damage, friction and wear, respectively, are derived from the principle of virtual power. The standard material is then defined as usual by state laws based on free energies and complementary laws based on dissipation potentials. In particular, we pick free energies and dissipation potentials that correspond to a non-local continuum damage model coupled to friction and wear. In addition, the boundary conditions at the contact interface creates a coupling between damage and wear. This is a key feature of our model, which makes it very useful in studies of fretting fatigue. By starting from a variational formulation of the governing equations, two different finite element algorithms are implemented. Both algorithms are based on a Newton method for semi-smooth equations. In the first algorithm the Newton method is applied to the entire system of equations, while in the second algorithm the system of equations is split into two different parts such that an elastic wear problem is solved for fixed damage followed by the solution of the damage evolution problem for the updated displacements and contact forces in an iterative process. The latter algorithm can be viewed as a Gauss-Seidel scheme. The numerical performance of the algorithms is investigated for three twodimensional examples of increasing complexity. Based on the numerical solutions, the behavior of the model is also discussed. For instance, it is shown numerically how the initiation of damage depends on the contact geometry, the coefficient of friction and the evolution of wear.
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