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• Appraisement of planar, bending and twisting cracks in 3D with isotropic and orthotropic damage models

  G. Barbat, M. Cervera, M. Chiumenti

  International Journal of Fracture (2018). (preprint) Vol. 210 (1-2), pp. 45–79

  
  

  Abstract

  This paper discusses the modeling of cracking in quasi-brittle materials using isotropic and orthotropic damage constitutive laws. A mixed strain/displacement finite element formulation is used, taking advantage of its enhanced precision and its enforced interelemental strain continuity. On the one hand, this formulation avoids the spurious mesh dependency of the computed solution associated to standard elements and does not require the use of tracking techniques. On the other hand, it greatly alleviates the spurious stress locking associated to the use of orthotropic models on standard finite elements. The performance of several isotropic and orthotropic damage constitutive laws is assessed through an extensive comparison with analytical solutions, numerical tests and experimental evidence reported in the literature. The behavior of the different damage models in terms of crack surface, collapse mechanism and force displacement curves is investigated performing 3D analyses in several conditions including Mode I, Mixed Mode and Mode III fracture. When performing the appraisement of planar, bending and twisting cracks, the enhanced accuracy of the mixed formulation allows for a distinct assessment of the several damage models considered. Aspects related to the behavior of damage models, such as the influence of Poisson’s ratio, the shape of the damage surface and the adoption of isotropic and orthotropic models are investigated and noteworthy conclusions are drawn

  Abstract
  This paper discusses the modeling of cracking in quasi-brittle materials using isotropic and orthotropic damage constitutive laws. A mixed strain/displacement finite element [...]

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• A novel positive/negative projection in energy norm for the damage modeling of quasi-brittle solids

  J. Wu, M. Cervera

  Int. J. Solids and Structures (2018). (preprint) Vol. 139–140, pp. 250–269

  
  

  Abstract

  The asymmetric tensile/compressive material behavior and microcracks closure-reopening (MCR) effects exhibited by quasi-brittle solids are of significant importance to the nonlinear responses of engineering structures under cyclic loading, e.g., earthquake excitations. Based on our previous work (Cervera et al., 1995; Faria et al., 1998; Wu et al., 2006) this work addresses a novel thermodynamically consistent unilateral damage model for concrete. In particular, the positive/negative projection (PNP) of the effective stress tensor and the additive bi-scalar damage constitutive relation are maintained owing to the conceptual simplicity and computational efficiency. It is found that the classical PNP widely adopted in the literature is not optimal for this damage model, since the resulting stiffness is not always of major symmetry. Consequently, a well-defined free energy potential does not exist in general cases and the model cannot be cast into the framework of thermodynamics with internal variables. Furthermore, the damage induced anisotropy cannot be captured, exhibiting excessive lateral deformationsunder uniaxial tension. To overcome the above issues, a novel PNP, variationally interpreted as the closest point projection of the effective stress in energy norm, is proposed with closed-form solution. With the novel PNP, the secant stiffness tensorof the proposed unilateral damage model always possesses major symmetry and exhibits orthotropic behavior under uniaxial tension and mixed tension/compression. The corresponding thermodynamics framework is then given, resulting in an energy release rate based rounded-Rankine type damage criterion appropriate for tensile failure in quasi-brittle solids. Several numerical examples of single-point verifications and benchmark tests are presented. It is demonstrated that the proposed model is capable of characterizing localized failureof concrete under proportional and non-proportional static loading, as well as the MCR effects under seismic cyclic loading.

  Abstract
  The asymmetric tensile/compressive material behavior and microcracks closure-reopening (MCR) effects exhibited by quasi-brittle solids are of significant [...]

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• Cracking of quasi-brittle structures under monotonic and cyclic loadings: A d+/d− damage model with stiffness recovery in shear

  M. Cervera, C. Tesei, G. Ventura

  Int. J. Solids and Structures (2017). (preprint) Vol. 135, pp. 148–171

  
  

  Abstract

  In the present paper, a new d+/d− damage model apt for quasi-brittle materials is described and its validation is carried out considering unreinforced concrete, reinforced concrete and masonry elements. Two independent scalar damage variables, d+ and d−, in combination with the split of the reversible strain tensor into its positive and negative counterparts, are adopted in order to simulate the pronounced dissimilar response under tension and compression, typical of these materials. An energy-equivalent framework is considered for representing the orthotropy induced in the material by the degradation process, with the consequence that a thermodynamically consistent constitutive operator, positive definite, symmetric and strain-driven, is derived. In addition to the degradation parameters, the permanent strain tensor is also contemplated by the model and a modification of the exponential softening modulus is proposed in order to treat the evolution of the two causes of dissipation, damage and irreversible deformations, in a coupled way. The formulation is integrated with a multidirectional damage procedure, addressed to extend the microcrack closure-reopening (MCR) capabilities of the model to shear cyclic conditions, characterized by orthogonal (or however intersecting) sets of cracks. Maintaining unaltered the dependence of the constitutive law from two scalar indeces, d+ and d−, this approach activates or deactivates a tensile(compressive) damage value on the base of the current maximum (minimum) principal strain direction. In correspondence with damage activation (crack opening) or deactivation (crack closure), a smooth transition is introduced, in order to avoid abrupt changes in stiffness and enhance the numerical performance and robustness of the multidirectional procedure. The adequacy of the proposed constitutive model in reproducing experimental results has been proven for both monotonic and cyclic loading conditions. The two examples of application involving cyclic loads, dominated by shear, constitute a validation of the multidirectional damage approach, showing how the suitable representation of unilateral effects and permanent deformations is essential to model the observed structural response in terms of maximum resistance, evolution of stiffness degradation and dissipation capacity.

  Abstract
  In the present paper, a new d+/d− damage model apt for quasi-brittle materials is described and its validation is carried out considering unreinforced [...]

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• Experimental validation of a FSW model with an enhanced friction model: application to a threaded cylindrical pin tool

  N. Dialami, M. Cervera, M. Chiumenti, A. Segatori, W. Osikowicz

  Metals (2017). (preprint) Vol. 7 (11), pp. 491

  
  

  Abstract

  This work adopts a fast and accurate two-stage computational strategy for the analysis of FSW (Friction stir welding) processes using threaded cylindrical pin tools. The coupled thermo-mechanical problem is equipped with an enhanced friction model to include the effect of non-uniform pressure distribution under the pin shoulder. The overall numerical strategy is successfully validated by the experimental measurements provided by the industrial partner (Sapa). The verification of the numerical model using the experimental evidence is not only accomplished in terms of temperature evolution but also in terms of torque, longitudinal, transversal and vertical forces.

  Abstract
  This work adopts a fast and accurate two-stage computational strategy for the analysis of FSW (Friction stir welding) processes using threaded cylindrical pin tools. The coupled [...]

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• Enhanced friction model for Friction Stir Welding (FSW) analysis: Simulation and experimental validation

  N. Dialami, M. Chiumenti, M. Cervera, A. Segatori, W. Osikowicz

  Int. J. Mechanical Sciences (2017). (preprint) Vol. 133, pp. 555-567

  
  

  Abstract

  Friction is one of the main heat generation mechanisms in Friction Stir Welding (FSW). This phenomenon occurs between the pin and the workpiece as the rotating tool moves along the weld line. An accurate friction model is essential for obtaining realistic results in a FSW simulation in particular temperature, forces and torque. In this work, a modified Norton's friction law is developed. The suggested enhanced friction model aims at providing not only the realistic temperature field but also the forces and torque. This model does not exclusively relate the frictional shear stress to the sliding velocity; conversely it takes into account the effect of non-uniform pressure distribution under the shoulder, as this latter has an important role in the process of heat generation. Longitudinal, transversal and vertical forces and torque are numerically calculated. The effect of the enhanced friction model is reflected in these forces. In particular, it leads to a more realistic estimation of the transversal and longitudinal forces in comparison with the results obtained using former models. The friction model is successfully validated by the experimental measurements provided by the industrial partner (Sapa). The experimental analysis is performed for the material characterization, the calibration of the friction model and, more generally, the assessment of the overall numerical strategy proposed for the FSW simulation.

  Abstract
  Friction is one of the main heat generation mechanisms in Friction Stir Welding (FSW). This phenomenon occurs between the pin and the workpiece as the rotating tool moves [...]

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• Numerical modelling and experimental validation in Selective Laser Melting

  M. Chiumenti, E. Neiva, E. Salsi, M. Cervera, E. Badia, J. Moya, Z. Chen, C. Lee, C. Davies

  Additive Manufacturing (2017). (preprint) Vol. 18, pp. 171-185

  
  

  Abstract

  In this work a finite-element framework for the numerical simulation of the heat transfer analysis of additive manufacturing processes by powder-bed technologies, such as Selective Laser Melting, is presented. These kind of technologies allow for a layer-by-layer metal deposition process to cost-effectively create, directly from a CAD model, complex functional parts such as turbine blades, fuel injectors, heat exchangers, medical implants, among others. The numerical model proposed accounts for different heat dissipation mechanisms through the surrounding environment and is supplemented by a finite-element activation strategy, based on the born-dead elements technique, to follow the growth of the geometry driven by the metal deposition process, in such a way that the same scanning pattern sent to the numerical control system of the AM machine is used. An experimental campaign has been carried out at the Monash Centre for Additive Manufacturing using an EOSINT-M280 machine where it was possible to fabricate different benchmark geometries, as well as to record the temperature measurements at different thermocouple locations. The experiment consisted in the simultaneous printing of two walls with a total deposition volume of 107 cm3 in 992 layers and about 33,500 s build time. A large number of numerical simulations have been carried out to calibrate the thermal FE framework in terms of the thermophysical properties of both solid and powder materials and suitable boundary conditions. Furthermore, the large size of the experiment motivated the investigation of two different model reduction strategies: exclusion of the powder-bed from the computational domain and simplified scanning strategies. All these methods are analysed in terms of accuracy, computational effort and suitable applications

  Abstract
  In this work a finite-element framework for the numerical simulation of the heat transfer analysis of additive manufacturing processes by powder-bed technologies, [...]

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• Finite element modeling of quasi-brittle cracks in 2D and 3D with enhanced strain accuracy

  M. Cervera, G. Barbat, M. Chiumenti

  Computational Mechanics (2017). (preprint) Vol. 60 (5), pp. 767–796

  
  

  Abstract

  This paper discusses the finite element modeling of cracking in quasi-brittle materials. The problem is addressed via a mixed strain/displacement finite element formulation and an isotropic damage constitutive model. The proposed mixed formulation is fully general and is applied in 2D and 3D. Also, it is independent of the specific finite element discretization considered; it can be equally used with triangles/tetrahedra, quadrilaterals/hexahedra and prisms. The feasibility and accuracy of the method is assessed through extensive comparison with experimental evidence. The correlation with the experimental tests shows the capacity of the mixed formulation to reproduce the experimental crack path and the force–displacement curves with remarkable accuracy. Both 2D and 3D examples produce results consistent with the documented data. Aspects related to the discrete solution, such as convergence regarding mesh resolution and mesh bias, as well as other related to the physical model, like structural size effect and the influence of Poisson’s ratio, are also investigated. The enhanced accuracy of the computed strain field leads to accurate results in terms of crack paths, failure mechanisms and force displacement curves. Spurious mesh dependency suffered by both continuous and discontinuous irreducible formulations is avoided by the mixed FE, without the need of auxiliary tracking techniques or other computational schemes that alter the continuum mechanical problem.

  Abstract
  This paper discusses the finite element modeling of cracking in quasi-brittle materials. The problem is addressed via a mixed strain/displacement finite element formulation [...]

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• Tracking multi-directional intersecting cracks in numerical modelling of masonry shear walls under cyclic loading

  S. Salaustros, M. Cervera, L. Pelà

  Meccanica (2017). (preprint) Vol. 53 (7), pp. 1757–1776

  
  

  Abstract

  In-plane cyclic loading of masonry walls induces a complex failure pattern composed of multiple diagonal shear cracks, as well as flexural cracks. The realistic modelling of such induced localized cracking necessitates the use of costly direct numerical simulations with detailed information on both the properties and geometry of masonry components. On the contrary, computationally efficient macro-models using standard smeared-crack approaches often result in a poor representation of fracture in the simulated material, not properly localized and biased by the finite element mesh orientation. This work proposes a possible remedy to these drawbacks of macro-models through the use of a crack-tracking algorithm. The macro-modelling approach results in an affordable computational cost, while the tracking algorithm aids the mesh-bias independent and localized representation of cracking. A novel methodology is presented that allows the simulation of intersecting and multi-directional cracks using tracking algorithms. This development extends the use of localized crack approaches using tracking algorithms to a wider field of applications exhibiting multiple, arbitrary and interacting cracking. The paper presents also a novel formulation including into an orthotropic damage model the description of irreversible deformations under shear loading. The proposed approach is calibrated through the comparison with an experimental test on a masonry shear wall against in-plane cyclic loading.

  Abstract
  In-plane cyclic loading of masonry walls induces a complex failure pattern composed of multiple diagonal shear cracks, as well as flexural cracks. The realistic modelling [...]

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• An enhanced finite element macro-model for the realistic simulation of localized cracks in masonry structures: A large-scale application

  S. Salaustros, L. Pelà, M. Cervera, P. Roca

  International Journal of Architectural Heritage (2017). (preprint) Vol. 12 (3), pp. 432-447

  
  

  Abstract

  Finite element macro-modeling approaches are widely used for the analysis of large-scale masonry structures. Despite their efficiency, they still face two important challenges: the realistic representation of damage and a reasonable independency of the numerical results to the used discretization. In this work, the classical smeared crack approach is enhanced with a crack-tracking algorithm, originating from the analysis of localized cracking in quasi-brittle materials. The proposed algorithm is for the first time applied to a large-scale wall exhibiting multiple shear and flexural cracking. Discussion covers structural aspects, as the response of the structure under different assumptions regarding the floor rigidity, but also numerical issues, commonly overlooked in the simulation of large structures, such the mesh-dependency of the numerical results.

  Abstract
  Finite element macro-modeling approaches are widely used for the analysis of large-scale masonry structures. Despite their efficiency, they still face two important challenges: [...]

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• Strain localization analysis of elastic-damaging frictional-cohesive materials: Analytical results and numerical verification

  J. Wu, M. Cervera

  Materials (2017). (preprint) Vol. 10 (4), pp. 434

  
  

  Abstract

  Damage-induced strain softening is of vital importance for the modeling of localized failure in frictional-cohesive materials. This paper addresses strain localization of damaging solids and the resulting consistent frictional-cohesive crack models. As a supplement to the framework recently established for stress-based continuum material models in rate form (Wu and Cervera 2015, 2016), several classical strain-based damage models, expressed usually in total and secant format, are considered. Upon strain localization of such damaging solids, Maxwell’s kinematics of a strong (or regularized) discontinuity has to be reproduced by the inelastic damage strains, which are defined by a bounded characteristic tensor and an unbounded scalar related to the damage variable. This kinematic constraint yields a set of nonlinear equations from which the discontinuity orientation and damage-type localized cohesive relations can be derived. It is found that for the “Simó and Ju 1987” isotropic damage model, the localization angles and the resulting cohesive model heavily depend on lateral deformations usually ignored in classical crack models for quasi-brittle solids. To remedy this inconsistency, a modified damage model is proposed. Its strain localization analysis naturally results in a consistent frictional-cohesive crack model of damage type, which can be regularized as a classical smeared crack model. The analytical results are numerically verified by the recently-proposed mixed stabilized finite element method, regarding a singly-perforated plate under uniaxial tension. Remarkably, for all of the damage models discussed in this work, the numerically-obtained localization angles agree almost exactly with the closed-form results. This agreement, on the one hand, consolidates the strain localization analysis based on Maxwell’s kinematics and, on the other hand, illustrates versatility of the mixed stabilized finite element method.

  Abstract
  Damage-induced strain softening is of vital importance for the modeling of localized failure in frictional-cohesive materials. This paper addresses strain localization of [...]

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