ABAQUS/Explicit: Advanced Topics

Lecture 9

Material Damage and Failure

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ABAQUS/Explicit: Advanced Topics

L9.2

Overview
Progressive Damage and Failure Damage Initiation for Ductile Metals Damage Evolution Element Removal Failure in Fasteners

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ABAQUS/Explicit: Advanced Topics

Progressive Damage and Failure

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ABAQUS/Explicit: Advanced Topics

L9.4

Progressive Damage and Failure

ABAQUS offers a general capability for modeling progressive damage and failure in engineering structures. Material failure refers to the complete loss of load carrying capacity that results from progressive degradation of the material stiffness. Stiffness degradation is modeled using damage mechanics. Progressive damage and failure can be modeled in: Bulk materials Continuum constitutive behavior used in conjunction with the Mises, Johnson-Cook, Hill, or Drucker-Prager plasticity models This is the primary focus of this lecture. Interface materials Cohesive elements with a traction-separation law This was discussed in Lecture 7, Constraints and Connections.
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ABAQUS/Explicit: Advanced Topics

L9.5

Progressive Damage and Failure

Two distinct types of bulk material failure can be modeled with ABAQUS/Explicit Ductile fracture of metals Void nucleation, coalescence, and growth Shear band localization Necking instability in sheet-metal forming Forming Limit Diagrams Marciniak-Kuczynski (M-K) criterion Damage in sheet metals is not discussed further in this seminar.

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ABAQUS/Explicit: Advanced Topics

L9.6

Progressive Damage and Failure

Components of material definition Undamaged constitutive behavior (e.g., elastic-plastic with hardening) Damage initiation (point A) Damage evolution (path AB) Choice of element removal (point B)
Keywords *MATERIAL *ELASTIC *PLASTIC *DAMAGE INITIATION,CRITERION=criterion *DAMAGE EVOLUTION *SECTION CONTROLS, ELEMENT DELETION=YES Typical material response showing progressive damage
Undamaged response

A
Damaged response

B
Multiple damage definitions are allowed

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ABAQUS/Explicit: Advanced Topics

Damage Initiation Criteria for Ductile Metals

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ABAQUS/Explicit: Advanced Topics

L9.8

Damage Initiation Criteria for Ductile Metals

Damage initiation defines the point of initiation of degradation of stiffness It is based on user-specified criteria Ductile or shear It does not actually lead to damage unless damage evolution is also specified Output variables associated with each criterion Useful for evaluating the severity of current deformation state Output
DMICRT
Ductile Shear

DMICRT 1 indicates damage has initiated

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Different damage initiation criteria on an aluminum double-chamber profile

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L9.9

Damage Initiation Criteria for Ductile Metals

Ductile criterion: Appropriate for triggering damage due to nucleation, growth, and coalescence of voids The model assumes that the equivalent plastic strain at the onset of damage is a function of stress triaxiality and strain rate.
Pressure stress

Stress triaxiality = p / q
Mises stress

The ductile criterion can be used with the Mises, Johnson-Cook, Hill, and Drucker-Prager plasticity models, including equation of state.

Ductile criterion for Aluminum Alloy AA7108.50-T6 (Courtesy of BMW)

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ABAQUS/Explicit: Advanced Topics

L9.10

Damage Initiation Criteria for Ductile Metals

Example: Axial crushing of an aluminum double-chamber profile Model details Steel base: C3D8R elements Enhanced hourglass control Elastic-plastic material Aluminum chamber: S4R elements Stiffness hourglass control Rate-dependent plasticity Damage initiation General contact Variable mass scaling
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Rigid plate with initial downward velocity Aluminum chamber

Cross section

Steel base: bottom is encastred.

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L9.11

Damage Initiation Criteria for Ductile Metals

Specify a damage initiation criterion based on the ductile failure strain.
*MATERIAL, NAME=ALUMINUM *DENSITY 2.70E-09 *ELASTIC 7.00E+04, 0.33 *PLASTIC,HARDENING=ISOTROPIC,RATE=0 : *DAMAGE INITIATION, CRITERION=DUCTILE 5.7268, 0.000, 0.001 4.0303, 0.067, 0.001 2.8377, 0.133, 0.001 : 4.4098, 0.000, 250 2.5717, 0.067, 250 1.5018, 0.133, 250 :
strain rate dependence of ductile criterion
7 6 strain at damage initiation 5 4 3 2 1 0 0 0.2 0.4 0.6 stress triaxiality strain rate=0.001/s strain rate=250/s

& pl Strain rate,

Stress triaxiality,

Ductile and shear criteria for Aluminum Alloy AA7108.50-T6 (Courtesy of BMW)

Equivalent fracture strain pl at damage initiation,

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ABAQUS/Explicit: Advanced Topics

L9.12

Damage Initiation Criteria for Ductile Metals

Shear criterion: Appropriate for triggering damage due to shear band localization The model assumes that the equivalent plastic strain at the onset of damage is a function of the shear stress ratio and strain rate. Shear stress ratio defined as:

s = (q + ks p) /max
The shear criterion can be used with the Mises, Johnson-Cook, Hill, and Drucker-Prager plasticity models, including equation of state.
ks = 0.3

Shear criterion for Aluminum Alloy AA7108.50-T6 (Courtesy of BMW)

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ABAQUS/Explicit: Advanced Topics

L9.13

Damage Initiation Criteria for Ductile Metals

Example (contd): Axial crushing of an aluminum double-chamber profile Specify a damage initiation criterion based on the ductile failure strain.
*MATERIAL, NAME=ALUMINUM : *DAMAGE INITIATION, CRITERION=DUCTILE 5.7268, 0.000, 0.001 4.0303, 0.067, 0.001 :
strain rate dependence of shear criterion
0.8 0.7 0.6 0.5 0.4 0.3 0.2 0.1 0 1.6 1.7

ks is a material parameter

strain at damage initiation

strain rate=0.001/s strain rate=250/s 1.8 1.9 2

*DAMAGE INITIATION, CRITERION=SHEAR, KS=0.3 0.2761, 1.424, 0.001 0.2613, 1.463, 0.001 0.2530, 1.501, 0.001 : & pl Strain rate, 0.2731, 1.424, 250 0.3025, 1.463, 250 Shear stress 0.3323, 1.501, 250 :

shear stress ratio

Ductile and shear criteria for Aluminum Alloy AA7108.50-T6 (Courtesy of BMW)

ratio, s

Equivalent fracture strain pl at damage initiation,

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ABAQUS/Explicit: Advanced Topics

L9.14

Damage Initiation Criteria for Ductile Metals

Example (contd): Axial crushing of an aluminum double-chamber profile

Ductile damage initiation criterion output:

DUCTCRT (D) The criterion for damage initiation is met when D 1.

Displacement scale factor: 0.25

Shear damage initiation criterion output :

SHRCRT (S) The criterion for damage initiation is met when S 1.
Ductile Shear

DUCTCRT
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SHRCRT

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L9.15

Damage Initiation Criteria for Ductile Metals

Example (contd): Axial crushing of an aluminum double-chamber profile

Damage initiation does not actually lead to damage unless damage evolution is also specified.

Aluminum double-chamber after dynamic impact

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Analysis results with damage initiation but no damage evolution

ABAQUS/Explicit: Advanced Topics

Damage Evolution

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ABAQUS/Explicit: Advanced Topics

L9.17

Damage Evolution
Damage evolution defines the post damage-initiation material behavior. That is, it describes the rate of degradation of the material stiffness once the initiation criterion is satisfied. The formulation is based on scalar damage approach:
Stress due to undamaged response

= (1 D)

The overall damage variable D captures the combined effect of all active damage mechanisms. When damage variable D = 1, material point has completely failed. In other words, fracture occurs when D = 1.

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ABAQUS/Explicit: Advanced Topics

L9.18

Damage Evolution
Elastic-plastic materials For a elastic-plastic material, damage manifests in two forms: Softening of the yield stress Degradation of the elasticity

Undamaged response

y0
( D = 0)

0
E

Degradation of elasticity

softening

(1 D) E

0pl

fpl

Schematic representation of elastic-plastic material with progressive damage.

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ABAQUS/Explicit: Advanced Topics

L9.19

Damage Evolution
The damage evolution law can be specified either in terms of fracture energy (per unit area) or equivalent plastic displacement. Both approaches take into account the characteristic length of the element. The formulation ensures that meshsensitivity is minimized.

y0
Gf

u fpl =

2G f

y0

u pl
Energy based damaged evolution (linear or exponential)

d
1

u pl

Displacement based damage evolution (tabular, linear, or exponential)

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ABAQUS/Explicit: Advanced Topics

L9.20

Damage Evolution
Example (contd): Axial crushing of an aluminum double-chamber profile Dynamic response with damage evolution
*MATERIAL, NAME=ALUMINUM : *DAMAGE INITIATION, CRITERION=DUCTILE : *DAMAGE EVOLUTION, TYPE=DISPLACEMENT, SOFTENING=LINEAR 0.1, *DAMAGE INITIATION, CRITERION=SHEAR, KS=0.3 : *DAMAGE EVOLUTION, TYPE=DISPLACEMENT, SOFTENING=LINEAR 0.1,
pl specify the effective plastic displacement, u f , at the point of failure (full degradation).

Linear form of damage evolution based on effective plastic displacement

d

u fpl

u pl

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ABAQUS/Explicit: Advanced Topics

L9.21

Damage Evolution
Example (contd): Axial crushing of an aluminum double-chamber profile With damage evolution, the simulation response is a good approximation of the physical response.

Simulation without damage evolution

Aluminum double-chamber after dynamic impact

Simulation with damage evolution

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ABAQUS/Explicit: Advanced Topics

L9.22

Damage Evolution
Example: Tearing of an X-shaped cross section

Tie constraints

Fix this end

Pull and twist this end

Failure modeled with different mesh densities

Video Clip

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ABAQUS/Explicit: Advanced Topics

L9.23

Damage Evolution
Example (contd): Tearing of an X-shaped cross section Comparison of reaction forces and moments confirms mesh insensitivity of the results.

RF1 coarse RF1 fine

RM3 coarse RM3 fine

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ABAQUS/Explicit: Advanced Topics

Element Removal

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ABAQUS/Explicit: Advanced Topics

L9.25

Element Removal
ABAQUS offers the choice to remove the element from the mesh once the material stiffness is fully degraded (i.e., once the element has failed). An element is said to have failed when all section points at any one integration point have lost their load carrying capacity. By default, failed elements are deleted from the mesh.

Video Clip

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ABAQUS/Explicit: Advanced Topics

L9.26

Element Removal
Removing failed elements before complete degradation The material point is assumed to fail when the overall damage variable D reaches the critical value Dmax. You can specify the value for the maximum degradation Dmax. The default value of Dmax is 1 if the element is to be removed from the mesh upon failure.
*SECTION CONTROLS, NAME=name, ELEMENT DELETION=YES, MAX DEGRADATION=Dmax

Refer to the section controls by name on the element section definition, for example:
*SOLID SECTION, ELSET=PLATE, MATERIAL=RHA, CONTROLS=RHAControls

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ABAQUS/Explicit: Advanced Topics

L9.27

Element Removal
Retaining failed elements You may choose not to remove failed elements from the mesh.
*SECTION CONTROLS, ELEMENT DELETION = NO

In this case the default value of Dmax is 0.99, which ensures that elements will remain active in the simulation with a residual stiffness of at least 1% of the original stiffness. Here Dmax represents the maximum degradation of the shear stiffness (threedimensional), the total stiffness (plane stress), or the uniaxial stiffness (one-dimensional). Failed elements that have not been removed from the mesh can sustain hydrostatic compressive stresses.

Copyright 2005 ABAQUS, Inc.

ABAQUS/Explicit: Advanced Topics

L9.28

Element Removal
Contact can occur on both the exterior and interior of regions modeled with material failure and element removal. The procedure for defining general contact for this type of problem was discussed in Lecture 4, Contact Modeling.
1 2

Define an element-based surface that includes the exterior and interior faces or define a node based surface that includes all nodes. Include this surface as part of the general contact definition.

When element-based surfaces are used to model eroding contact the contact active contact domain evolves during the analysis as elements fail.
newly exposed faces

Surface topology before the yellow elements have failed

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Surface topology after failure

ABAQUS/Explicit: Advanced Topics

L9.29

Element Removal
Examples of surface erosion in solid elements

Eroding projectile impacting eroding plate

Drilling process
drill

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ABAQUS/Explicit: Advanced Topics

L9.30

Element Removal
Output The output variable SDEG contains the value of D. The output variable STATUS indicates whether or not an element has failed. STATUS = 0 for failed elements STATUS = 1 for active elements

Video Clip

failed elements
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Damage in Fasteners

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ABAQUS/Explicit: Advanced Topics

L9.32

Damage in Fasteners
Rigid or elastic fasteners may introduce non-physical noise in the solution. Behavior of fasteners should be modeled based on experimental testing.

S 0

N 90
self-pierced rivet

Experimental force-displacement curves for a self-pierced rivet. Response depends on loading angle . (Courtesy of BMW & Fraunhofer Institute, Freiburg)
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ABAQUS/Explicit: Advanced Topics

L9.33

Damage in Fasteners
Fastener failure implementation is aimed at capturing experimental force-displacement response of fasteners Model combines plasticity and progressive damage Response depends on loading angle (normal/shear) Stages: Rigid plasticity with variable hardening Damage initiation
45o
N 90 S 0

Fastener

F
0o

Plasticity + Damage

Progressive damage evolution using fracture energy

90o
Plasticity
damage initiation boundary

Schematic representation of the predicted numerical response

Copyright 2005 ABAQUS, Inc.

u pl

ABAQUS/Explicit: Advanced Topics

L9.34

Damage in Fasteners
Example: Multibody mechanism Damage initiation and evolution are added to the definition of four connectors. Section definition for the original rigid JOIN connector:
*CONNECTOR SECTION, ELSET=RR-LD join, RR-LD

UJOINT

JOIN CYLINDRICAL TRANSLATOR

HINGE PLANAR Connector elements in a multibody mechanism

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ABAQUS/Explicit: Advanced Topics

L9.35

Damage in Fasteners
Example (contd): Multibody mechanism
Modify section definition to account for damage:
*CONNECTOR SECTION, ELSET=RR-LD, BEHAVIOR=JOIN_DAM CARTESIAN RR-LD, *CONNECTOR BEHAVIOR, NAME=JOIN_DAM *CONNECTOR ELASTICITY, RIGID 1,2,3 *CONNECTOR DAMAGE INITIATION ,100000 *CONNECTOR POTENTIAL 1, 2, 3, *CONNECTOR DAMAGE EVOLUTION, TYPE=ENERGY 100, With the Cartesian connection the previously constrained translational components of relative motion are available.

All three translational components of relative motion will behave rigidly before damage initiation.

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ABAQUS/Explicit: Advanced Topics

L9.36

Damage in Fasteners
Example (contd): Multibody mechanism
Modify section definition to account for damage:
*CONNECTOR SECTION, ELSET=RR-LD, BEHAVIOR=JOIN_DAM CARTESIAN RR-LD, *CONNECTOR BEHAVIOR, NAME=JOIN_DAM *CONNECTOR ELASTICITY, RIGID 1,2,3 *CONNECTOR DAMAGE INITIATION ,100000 *CONNECTOR POTENTIAL 1, 2, 3, *CONNECTOR DAMAGE EVOLUTION, TYPE=ENERGY 100, Damage begins when connector force reaches 100,000 The same connector damage behavior for all three components of relative motion.

Copyright 2005 ABAQUS, Inc.

ABAQUS/Explicit: Advanced Topics

L9.37

Damage in Fasteners
Example (contd): Multibody mechanism
Modify section definition to account for damage:
*CONNECTOR SECTION, ELSET=RR-LD, BEHAVIOR=JOIN_DAM CARTESIAN RR-LD, *CONNECTOR BEHAVIOR, NAME=JOIN_DAM *CONNECTOR ELASTICITY, RIGID 1,2,3 *CONNECTOR DAMAGE INITIATION ,100000 *CONNECTOR POTENTIAL 1, 2, 3, *CONNECTOR DAMAGE EVOLUTION, TYPE=ENERGY 100,

Gc
U

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ABAQUS/Explicit: Advanced Topics

L9.38

Damage in Fasteners
Video Clip

Example (contd): Multibody mechanism

undeformed

After JOIN failure

After HINGE failure

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