Presentation: Contact Mechanics of Impacting Slender Rods: Measurement and Analysis

Sanders, A., I. Tibbitts, D. Kakarla, S. Siskey, J. Ochoa, K. Ong, and R. Brannon. (2011). “Contact mechanics of impacting slender rods: measurement and analysis.” Society for Experimental Mechanics Annual Meeting. Uncasville, CT, June 13-16.


Images of a typical contact patch

To validate models of contact mechanics in low speed structural impact, slender rods with curved tips were impacted in a drop tower, and measurements of the contact and vibration were compared to analytical and finite element (FE) models. The contact area was recorded using a thin-film transfer technique, and the contact duration was measured using electrical continuity. Strain gages recorded the vibratory strain in one rod, and a laser Doppler vibrometer measured velocity. The experiment was modeled analytically using a quasi-static Hertzian contact law and a system of delay differential equations. The FE model used axisymmetric elements, a penalty contact  algorithm, and explicit time integration. A small submodel taken from the initial global model economically refined the analysis in the small contact region. Measured contact areas were within 6% of both models’ predictions, peak speeds within 2%, cyclic strains within 12 microstrain (RMS value), and contact durations within 2 µs. The accuracy of the predictions for this simple test, as well as the versatility of the diagnostic tools, validates the theoretical and computational models, corroborates instrument calibration, and establishes confidence thatthe same methods may be used in an experimental and computational study of the impact mechanics of artificial hip joint.

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Global model results comparison with analytical and experimental results for speed at the midpoint of one of the rods

Publication: Uniaxial and Triaxial Compression Tests of Silicon Carbide Ceramics under Quasi-static Loading Condition

M.Y. Lee, R.M. Brannon and D.R. Bronowski

Explosive failure of the SICN-UC02 specimen (12.7 mm in diameter and 25.4 mm in length) subjected to the unconfined uniaxial compressive stress condition

To establish mechanical properties and failure criteria of silicon carbide (SiC-N) ceramics, a series of quasi-static compression tests has been completed using a high-pressure vessel and a unique sample alignment jig.  This report summarizes the test methods, set-up, relevant observations, and results from the constitutive experimental efforts. Combining these quasistatic triaxial compression strength measurements with existing data at higher pressures naturally results in different values for the least-squares fit to this function, appropriate over a broader pressure range. These triaxial compression tests are significant because they constitute the first successful measurements of SiC-N compressive strength under quasistatic conditions. Having an unconfined compressive strength of ~3800 MPa, SiC-N has been heretofore tested only under dynamic conditions to achieve a sufficiently large load to induce failure. Obtaining reliable quasi-static strength measurements has required design of a special alignment jig and loadspreader assembly, as well as redundant gages to ensure alignment. When considered in combination with existing dynamic strength measurements, these data significantly advance the characterization of pressure-dependence of strength, which is important for penetration simulations where failed regions are often at lower pressures than intact regions.

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Publication: Experimental Assessment of Unvalidated Assumptions in Classical Plasticity Theory

R. Brannon, J.A. Burghardt, D. Bronowski, and S. Bauer

Common isotropic yield surfaces. Von Mises and Drucker-Prager models are often used for metals. Gurson’s function, and others like it, are used for porous media. Tresca and Mohr-Coulomb models approximate the yield threshold for brittle media. Fossum’s model, and others like it, combine these features to model realistic geological media.

This report investigates the validity of several key assumptions in classical plasticity theory regarding material response to changes in the loading direction. Three metals, two rock types, and one ceramic were subjected to non-standard loading directions, and the resulting strain response increments were displayed in Gudehus diagrams to illustrate the approximation error of classical plasticity theories. A rigorous mathematical framework for fitting classical theories to the data,thus quantifying the error, is provided. Further data analysis techniques are presented that allow testing for the effect of changes in loading direction without having to use a new sample and for inferring the yield normal and flow directions without having to measure the yield surface. Though the data are inconclusive, there is indication that classical, incrementally linear, plasticity theory may be inadequate over a certain range of loading directions. This range of loading directions also coincides with loading directions that are known to produce a physically inadmissible instability for any nonassociative plasticity model.

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Publication: Determining a Surrogate Contact Pair in a Hertzian Contact Problem

Sanders, A. P. and R. M. Brannon (2011). “Determining a Surrogate Contact Pair in a Hertzian Contact Problem.” Journal of Tribology 133(2): 024502-024506.

Hertzian substitution concept: An arbitrary contact pair (a) with given principal curvatures and orientation, is substituted with a simpler contact pair (b) consisting of a spheroid and a plane

Laboratory testing of contact phenomena can be prohibitively expensive if the interacting bodies are geometrically complicated. This work demonstrates means to mitigate such problems by exploiting the established observation that two geometrically dissimilar contact pairs may exhibit the same contact mechanics. Specific formulas are derived that allow a complicated Hertzian contact pair to be replaced with an inexpensively manufactured and more easily fixtured surrogate pair, consisting of a plane and a spheroid, which has the same (to second-order accuracy) contact area and pressure distribution as the original complicated geometry. This observation is elucidated by using direct tensor notation to review a key assertion in Hertzian theory; namely, geometrically complicated contacting surfaces can be described to second-order accuracy as contacting ellipsoids. The surrogate spheroid geometry is found via spectral decomposition of the original pair’s combined Hessian tensor. Some numerical examples using free-form surfaces illustrate the theory, and a laboratory test validates the theory under a common scenario of normally compressed convex surfaces. This theory for a Hertzian contact substitution may be useful in simplifying the contact, wear, or impact testing of complicated components or of their constituent materials.

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Publication: A model for statistical variation of fracture properties in a continuum mechanics code

H.W. Meyer Jr. and R.M. Brannon

[This post refers to the original on-line version of the publication. The final (paper) version with page numbers and volume is found at Some further details and clarifications are in the 2012 posting about this article]

Simulation results for a reference volume of 0.000512 cm^3 ; sf is the size effect factor

Continuum mechanics codes modeling failure of materials historically have considered those materials to be homogeneous, with all elements of a material in the computation having the same failure properties. This is, of course, unrealistic but expedient. But as computer hardware and software has evolved, the time has come to investigate a higher level of complexity in the modeling of failure. The Johnsone-Cook fracture model is widely used in such codes, so it was chosen as the basis for the current work. The CTH finite difference code is widely used to model ballistic impact and penetration, so it also was chosen for the current work. The model proposed here does not consider individual flaws in a material, but rather varies a material’s Johnsone-Cook parameters from element to element to achieve in homogeneity. A Weibull distribution of these parameters is imposed, in such a way as to include a size effect factor in the distribution function. The well-known size effect on the failure of materials must be physically represented in any statistical failure model not only for the representations of bodies in the simulation (e.g., an armor plate), but also for the computational elements, to mitigate element resolution sensitivity of the computations.The statistical failure model was tested in simulations of a Behind Armor Debris (BAD) experiment, and found to do a much better job at predicting the size distribution of fragments than the conventional (homogeneous) failure model. The approach used here to include a size effect in the model proved to be insufficient, and including correlated statistics and/or flaw interactions may improve the model.

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Publication: On the thermodynamic requirement of elastic stiffness anisotropy in isotropic materials

Measure of anisotropy for Zircon, Quartz, Uranium, Titanium, Hornblende, and Copper.

T. Fuller and R.M. Brannon

In general, thermodynamic admissibility requires isotropic materials develop reversible deformation induced anisotropy (RDIA) in their elastic stiffnesses. Taking the elastic potential for an isotropic material to be a function of the strain invariants, isotropy of the elastic stiffness is possible under distortional loading if and only if the bulk modulus is independent of the strain deviator and the shear modulus is constant. Previous investigations of RDIA have been limited to applications in geomechanics where material non-linearityand large deformations are commonly observed. In the current paper, the degree of RDIA in other materials is investigated. It is found that the resultant anisotropy in materials whose strength does not vary appreciably with pressure, such as metals, is negligible, but in materials whose strength does vary with pressure, the degree of RDIA can be significant. Algorithms for incorporating RDIA in a classical elastic–plastic model are provided.

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Publication: A convected particle domain interpolation technique to extend applicability of the material point method for problems involving massive deformations

A. Sadeghirad, R. M. Brannon, and J. Burghardt

Three snapshots of the model with 248 particles in simulation of the radial expansion of a ring problem using: (a) CPDI method and (b) cpGIMP

A new algorithm is developed to improve the accuracy and efficiency of the material point method for problems involving extremely large tensile deformations and rotations. In the proposed procedure, particle domains are convected with the material motion more accurately than in the generalized interpolation material point method. This feature is crucial to eliminate instability in extension, which is a common shortcoming of most particle methods. Also, a novel alternative set of grid basis functions is proposed for efficiently calculating nodal force and consistent mass integrals on the grid. Specifically, by taking advantage of initially parallelogram-shaped particle domains, and treating the deformation gradient as constant over the particle domain, the convected particle domain is a reshaped parallelogram in the deformed configuration. Accordingly, an alternative grid basis function over the particle domain is constructed by a standard 4-node finite element interpolation on the parallelogram. Effectiveness of the proposed modifications is demonstrated using several large deformation solid mechanics problems.

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Publication: Validating Theories for Brittle Damage

R.M. Brannon, J.M. Wells, and O.E. Strack

Realistic-looking, uneven damage zones in Brazilian simulations compare favorably with laboratory data for observable damage

Validating simulated predictions of internal damage within armor ceramics is preferable to simply assessing a models ability to predict penetration depth, especially if one hopes to perform subsequent ‘‘second strike’’ analyses. We present the results of a study in which crack networks are seeded by using a statistically perturbed strength, the median of which is inherited from a deterministic ‘‘smeared damage’’ model, with adjustments to reflect experimentally established size effects. This minor alteration of an otherwise conventional damage model noticeably mitigates mesh dependencies and, at virtually no computational cost, produces far more realistic cracking patterns that are well suited for validation against X-ray computed tomography (XCT) images of internal damage patterns. For Brazilian, spall, and indentation tests, simulations share qualitative features with externally visible damage. However, the need for more stringent quantitative validation, software quality testing, and subsurface XCT validation, is emphasized.

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Publication: On a viscoplastic model for rocks with mechanism-dependent characteristic times

A. F. Fossum and R. M. Brannon

Rate Dependance

This paper summarizes the results of a theoretical and experimental program at Sandia National Laboratories aimed at identifying and modeling key physical features of rocks and rock-like materials at the laboratory scale over a broad range of strain rates. The mathematical development of a constitutive model is discussed and model predictions versus experimental data are given for a suite of laboratory tests. Concurrent pore collapse and cracking at the microscale are seen as competitive micromechanisms that give rise to the well-known macroscale phenomenon of a transition from volumetric compaction to dilatation under quasistatic triaxial compression. For high-rate loading, this competition between pore collapse and microcracking also seems to account for recently identified differences in strain-rate sensitivity between uniaxial-strain ‘‘plate slap’’ data compared to uniaxial-stress Kolsky bar data. A description is given of how this work supports ongoing efforts to develop a predictive capability in simulating deformation and failure of natural geological materials, including those that contain structural features such as joints and other spatial heterogeneities.

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Publication: Verification Of Frame Indifference For Complicated Numerical Constitutive Models

K. Kamojjala, R. M. Brannon (2011)

Snapshot of the deformation in time

The principle of material frame indifference require spatial stresses to rotate with the material, whereas reference stresses must be insensitive to rotation. Testing of a classical uniaxial strain problem with superimposed rotation reveals that a very common approach to strong incremental objectivity taken in finite element codes to satisfy frame indifference(namely working in an approximate un-rotated frame) fails this simplistic test. A more complicated verification example is constructed based on the method of manufactured solutions (MMS) which involves the same character of loading at all points, providing a means to test any nonlinear-elastic arbitrarily anisotropic constitutive model.

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