07-A Aerospace 048

14th International LS-DYNA Users Conference Session: Aerospace
Material Testing for Development and Calibration of

Material models for Plastic Deformation and Failure
Amos Gilat and Jeremy Seidt
The Ohio State University Department of Mechanical and Aerospace Engineering

Columbus OH, USA
Abstract
Material testing at various, loading conditions, temperatures, and strain rates is used for
studying plastic deformation and failure of materials. The data from such tests is used for
developing and calibrating material model that are utilized in numerical codes that are used for
simulations of practical applications. The presentation will review experimental techniques used
in such testing with emphasis on the integration of Digital Image Correlation (DIC) for
measuring full-field deformations and the development of new tests. Of special interest is the
testing needed for supporting the new deformation and failure model MAT224 in LS-DYNA.
This material model is based on experimental determination of a failure surface that gives the
equivalent plastic strain to failure as a function of stress triaxiality and the Lode parameter. It is
done by testing specimens that are subjected to uniform and nonuniform states of stress and
deformation and determining the failure state (deformation and stress) from matching the
simulation of the test with the DIC and load measurements. Testing can be done at room
temperature or, by using a special furnace, at elevated temperatures (up to 850C). In addition,
a new experimental setup in which full-field deformation and full-field temperature are measured
simultaneously on the surface of a specimen during a tensile test is introduced. Results from
testing specimens made of stainless steel show a significant temperature increase in the neck
area in a quasi-static tension test. In most material models (e.g. Johnson Cook) the effect of
strain hardening and temperature softening are uncoupled. The data that is typically used for
determining the parameters in the models is obtained from experiments where strain hardening
and temperature are coupled. The results from the new experimental setup can be used for
uncoupling the effect of strain hardening and thermal softening during plastic deformation.
Background
Numerical simulation of the response of materials under loads has reached a level of maturity at
which it can be used with confidence for design purposes. Numerical codes like LS-DYNA
include many material models for deformation and failure (constitutive relations) that can be
selected for specific applications. The various models require input parameters that are specific
to the material that is being simulated. The accuracy of the simulations depends on the values of
the input parameters which are determined from experimental data.
The focus of the present paper is on the testing configurations and techniques that have
been developed recently for the purpose of providing accurate data for determining the
parameters in material models for deformation and failure. Of special interest is MAT224 which
is a relatively new deformation and failure model in LS-DYNA. The input requires stress strain
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Session: Aerospace 14th International LS-DYNA Users Conference
curves from tests at different strain rates and temperatures and values of equivalent failure strain
at various state of stress (various combinations of stress triaxiality and Lode parameter).
Uniaxial Stress Tests at Various Strain Rates and Temperatures
Uniaxial (tension, compression, shear) tests can be done at various strain rates and temperatures.
At quasi-static strain rates between 10-4 s-1 and 1 s-1 they are done using a hydraulic machine. At
strain rates above 500 s-1 they are done using the split Hopkinson bar (SHB) technique. A special
machine was developed for testing in tension and compression at intermediate strain rates of 10
s-1 to 200 s-1. The technique is a hybrid of a SHB and a hydraulic machine. A specimen that is
placed between the end of a long bar and a hydraulic actuator is loaded by the hydraulic actuator,
Fig. 1. As the specimen is loaded, a wave propagates to the end of the bar and reflects back. The
force in the specimen is measured by strain gages that are placed on the bar and the strain in
measured directly on the specimen with DIC. The actual setup is shown in Figs. 2 and 3.
Fig. 1: Schematic of the intermediate strain rate apparatus.
Fig. 2: Intermediate strain rate apparatus. Fig. 3: Intermediate strain rate apparatus.
The bar is more than 40 m long which allows a test duration (until the reflected wave arrives at
the strain gages that measure the force) of more than 0.016 s. At a strain rate of 20 s-1 it provides
enough time for the specimen to deform to a strain of 0.3. Results from tensile testing of HHS at
various strain rates are shown in Figs. 4.
Fig. 4: Tensile stress strain curves for HHS at different strain rates.
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14th International LS-DYNA Users Conference Session: Aerospace
Data for Determining the Failure Surface
The data for determining the failure surface is obtained from tension tests of notched flat and
notched round specimens with different notch dimensions, plane strain tension experiments with
smooth and notched specimens with different notch sizes, and biaxial tension-torsion and
compression-torsion tests and punch tests. Digital Image Correlation (DIC) is used in all the tests
for a direct measurement of the deformation (full field) on the surface of the specimens. The DIC
data together with numerical simulation of the experiments is used for determining the state of
stress (triaxiality and Lode parameter) and deformation in the specimens throughout the test and
at the instant of fracture. For example, a comparison between DIC experimental data and
numerical simulation is shown in Fig. 5. DIC data from tensile testing of flat-notched-specimens
with different notch sizes is shown in Fig. 6.
Fig. 5: DIC data and numerical simulation of a tensile test.
Fig. 6: DIC data from tensile testing of flat-notched-specimens.
Full-Field Deformation and Temperature Measurements
A new experimental setup, in which full-field deformation and full-field temperature are
measured simultaneously on the surface of a specimen during tensile tests at various strain rates
has been recently developed. The setup consists of a flat thin specimen and visual cameras on
one side of the specimen and a high speed IR camera on the other side. The set up for a high
strain rate test with the tensile SHB technique is shown is Fig. 7. Synchronized DIC and IR
images recorded in a test are shown in Fig. 8. Results from testing a specimen made of stainless
steel at a strain rate of about 3000 s-1 show that the strain in the necking region of the specimen
exceeds 0.6 and the temperature exceeds 300C. The results from these tests provide data that
June 12-14, 2016 1-3

Session: Aerospace 14th International LS-DYNA Users Conference
can be used for uncoupling the effects of strain hardening and temperature softening in plasticity
models.
Fig. 7: Tensile Split Hopkinson bar with full-field deformation and temperature measurements.
Fig. 8: DIC processed images recorded by the visual camera and IR camera images at different
times during the test.
Acknowledgements
The development of the testing techniques for the data needed for MAT224 was supported by the
U.S.A. Federal Aviation Administration, Grants No. 06-G-004 and 11-G-003. The authors are
grateful to Mr. Bill Emmerling, Dr. Chip Queitzsch, and Mr. Don Altobelli of the FAA. The
development of the intermediate strain rate test was done by Mr. Thomas Matrka with support
from NASA, Grant No. NNX08AB50A.
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14th International LS-DYNA Users Conference Session: Aerospace

Material Testing for Development and Calibration of

The Ohio State University Department of Mechanical and Aerospace Engineering

June 12-14, 2016 1-1

Uniaxial Stress Tests at Various Strain Rates and Temperatures

Fig. 1: Schematic of the intermediate strain rate apparatus.

1-2 June 12-14, 2016

Data for Determining the Failure Surface

Fig. 5: DIC data and numerical simulation of a tensile test.

Fig. 6: DIC data from tensile testing of flat-notched-specimens.

Full-Field Deformation and Temperature Measurements

June 12-14, 2016 1-3

1-4 June 12-14, 2016

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