Tension Test Basics Imp

Keynote:
Plastics & Simulation

Hubert Lobo DatapointLabs
p
Accurate FEA of Engineering
Plastics Seminar
October 14,
14 2014
Plastics and Simulation
strengthening the materials core of manufacturing enterprises
What makes plastics unique
Behavioral classes
Ductile polymer
Brittle polymer
Elastomer
Comparison
400%
Testing of polymers
Test specimens
Making test specimens
Testing variables
Test speeds
Test temperature
Environmental conditioning
In-vivo
Linear
Elastic models
Non-linear
Non-linear
Non
linear models
MISO modeling
ANSYS CAE Modeler
Polymer elasto
elasto-plasticity
plasticity
35
30
Engineering S
Stress (MPa)
25
20
data
15
Plastic Point
10
5
0
0.0
5.0
10.0
Engineering Strain (%)
15.0
20.0
Comparing PC to Al
Non-linear
True Strain (% )
True Stre s s (M Paa)
True Stre s s (M
M Pa)
The question of yield
True Strain (% )
Non-linear
Determining onset of plasticity

800
Load (N)
L
600
400
200
0
0
200
400
600
800
1000
time (sec)
extension
n (mm)
2
1.5
1
0.5
0
0
200
400
600
800
1000
time (sec)
Non-linear
Residual extension
plas10
2.5
extension, mm
1.5
0.5
0
0
2000
4000
6000
8000
time, s
Non-linear
Non-linear
Non
linear elastic limit
35
stres
ss MPa
30
25
20
15
10
5
0
0
10
20
30
strain %
40
Elasto-plastic models for plastics

35
Engineering Stress ((MPa)
30
25
20
data
15
Plastic Point
10
5
0
0.0
5.0
10.0
15.0
20.0
Pragmatic elasto
elasto-plasticity
plasticity
Tangent modulus basis
Secant modulus basis

40
Tru
ue Stress (MPa
a)
35
30
Model
25
Data
20
15
10
5
0
0.000
0.020
0.040
0.060
0.080
0.100
0.120
0.140
True Strain
Fidelity to plastic point
Fidelity to curve shape
Post yield ductile behavior

70
60
Stress MPa
50
40
30
UTM1-39
UTM1
39.62
62-1
1
20
UTM1-39.62-2
10
0
0
0.2
0.4
0.6
0.8
1.2
Strain mm/mm
1.4
1.6
Digital Image Correlation(DIC)
Measuring post
post-yield
yield stress
stress-strain
strain
180
160
True Stress (MPa))

T
140
120
100
80
1 mm GL
2 mm GL
60
4 mm GL
40
25 mm GL
50 mm GL
20
0
0.0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
True Strain (unitless)
Modeling up to yield
Modeling post
post-yield
yield
Hyperelastic
Modeling Elastomers
Hyperelastic Testing
Hyperelastic
Tensile test
Tensile Test
Biaxial tension test
Hyperelastic
Compressive test
Biaxial v.
v Compression Testing
300
250
Stress (psi)
200
150
biaxial measured by cruciform

100
biaxial calculated from compression

50
0
0
0.1
0.2
0.3
0.4
strain (mm/mm)
0.5
0.6
Hyperelastic
Planar tension
Typical rubber data
Rubber Modeling
Hyperelastic
Volumetric Test
Volumetric data
Hyperelastic
Modeling strategy
know your real life strains before you test
Hyperelastic
Mullins effect
to precycle or not to precycle

Hyperelastic
Model validation in ANSYS
Modeling brittle polymers
Linear elastic or bilinear (BISO)
Conclusions
Plastics and Simulation-2

Hubert Lobo
Choosing the right properties

Properties change over product operational
temperature
Properties change with environmental
exposure
Orientation (fiber
(fiber-filled
filled plastics)
Visco-elastic (time-based behavior)
Creep
Stress relaxation
Effect of strain rate

Effect of temperature
Properties and dependencies
change with temperature
Modulus
Ductile-brittle
transitions
Rate
R dependency
d
d
Effect of the environment

Properties and dependencies change can
change
Modulus
Ductile-brittle transitions
Data
D t you need
d is
i specific
ifi to
t your application
li ti
test exposed specimens instead of virgin material
Nylon: effect of moisture
UHMWPE: effect of in
in-vivo
vivo
Time based effects

Stress relaxation
Stress will relax over time
1E+10
Creep
Material under load will
flow over time
1E-07
G (Pa)
1E-08
1E+08
J (Pa-1)
1E+09
1E-09
1E+07
1E-07
1E-05
1E-03
1E-01
Time(s)
1E+01
1E+03
1E+05
1E-07
1E-05
1E-03
1E-01
Time (s)
1E+01
1E+03
1E+05
Visco elasticity
Visco-elasticity
In small strain (linear visco-elastic) situations
Applied strain (stress) is recoverable
A time-temperature
ti
t
t
correlation
l ti exists
it
Higher temperature = longer time
Lowering temperature = short time
Torsional Mode
Torsional DMA
Temperature: -125 to 600C

Frequency: 0.01 to 500 rad/s
Steady or dynamic modes
Torque range: 2 to 2000 gm-cm
Specimens
25 mm diam. Disc
Torsional (flex) bar
Data
G-G data
Shear stress relaxation
Tension/Compression Mode
Dynamic Tensile m/c
Frequency: 0.01-200 Hz
Load: 0-250 N
Crosshead speed
p
0-3 m/s
Displacement: 12.7 mm
Temperature: -80 to 250C
Specimens
ASTM type V tensile bar
Compression cube (25mm depending on stiffness)
Data
E E (tensile loss/storage modulus)
Tensile relaxation modulus E f(t)
TTS (Time Temperature Superposition)

Short time stress relaxation experiments
Varying temperatures to change stiffness
Alternate
Al
time
i shifting
hif i to create mastercurve
PTFE master
master-curve
curve
Shift factors
Viscoelastic data for ANSYS

Normalized modulus
data fit to 6 parameter
Prony series
Used for simulating
short or long term
events
Can apply WLF shift
factors for different
temperatures
Visco-elasticity & environmental

effects
ff
Visco-elastic
Limitations
depends on linear viscoelastic theory

can predict non-linear effects
cannot predict large strain
deformation
cannot predict failure
g
great caution when used with
hyperelasticity or other large
deformation model
Creep Regimes
Primary
short time
Secondary
sustained uniform strain
Tertiary
y
localization and failure
Creep Modeling
Creep
p Strain vs. Time Fit to Time Hardeningg Model
5.0
cr
45
4.5
4.0
Strain
n (%)
3.5
3.0
2.5
14.3 MPa, 60C, Replicate 1

24 1 MPa,
24.1
MPa 60
60C
C, Replicate 1
2.0
1.5
1.0
0.5
0.0
1E-02
1E-01
1E+00
1E+01
1E+02
1E+03
Time (Hours)
C1
c2
c3
Fiber filled plastics

Spatial orientation of fibers
Properties vary spatially
Can
C approximate:
i t
Worst case- use cross-flow data
Use DIGIMAT to take injection-molding

orientations to FEA
Basic DIGIMAT MX TestPak

Protocoll
Mold 100X200X3.16mm
plaques
l
Edge gated on 100 mm
end
Long flow length
Fully developed flow
Highly fiber orientation
Cut test specimens by

CNC
5 specimens each (0,
90 ,other
orientations )
orientations)
Obtain true stress-strain
data
Stress-strain
Stress
strain data
DIGIMAT MX TestPak outputs

CAD drawings of plaque and specimens
Plaque molding conditions
True stress strain
i d
data (M-204)
( 204) at 23C
0, 90 orientation from plaque
DIGIMAT MX Reverse Engineering

g
g
Data is ready for FEA
DIGIMAT TestPak options
Additional directions (10

(10,, 20
20,, 45
45))
Thermomechanical (from 40 to 150C)
Strain rate dependent (0.01
Strain-rate
(0 01 to 100/s)
3 point bend data (quasi isotropy)
T il bar
Tensile
b data
d t (coarse
(
fit)
Visco-elasticity
Low cycle fatigue (Lemaitre-Chaboche)
High cycle fatigue (under development)
Handling weld lines & failure

Test double-gated tensile
bars
Actual process conditions
Obtain tensile strength
g at
failure
Now, obtain weld line

location from injection
j
mold analysis
Model weld line with
cohesive element
Apply fail strength to
element
Handling failure in elastomers

Perform tear strength
test on rubber
ASTM D624 Type C
bow-tie
Obtain test data
Credits: Nair, Bestelmeyer, Lobo (2009)

Handling failure in elastomers

Model failure with
cohesive elements
Obtain fail strength to
elements
Coupling definitions
Cohesive Elements
Apply to real-life model

Damage path must be
known or postulated
Failure mode during the tear test (ASTM D624 Type C Specimen)
Credits: Nair, Bestelmeyer, Lobo (2009)

Plastics Rate Effects

Modulus may depend on rate
Plastics Rate Effects

Fail strain may be rate dependent
Effect of fiber fillers
Higher modulus
Small strain to failure
Brittle
i l failure
f il
No post-yield behavior
Anisotropy
Material Testing
Instron servo-hydraulic UTM

Dynamic load cell
Tensile
il strain
i rate to 100/s
100/
-40 to 150C
gate region
g
g
Test Specimens
ASTM D638Type V
Preparation
CNC from
f
plaque
l
CNC from part
Molded
Variability
processing
orientation
thickness
E1
E2
MAT 24 Ductile plastics
Modulus is not rate dependent

Large
g strains to failure
Post-yield necking
Plasticity curves vary with strain rate
Failure strain independent of strain rate
MAT 24 Choosing EMOD

35
Engineering Stress ((MPa)
30
25
20
data
15
Plastic Point
10
5
0
0.0
5.0
10.0
15.0
20.0
MAT 24 Plasticity
Discretize curve
Calculate EPS for each ES
EPSmax
S
> FAIL
A
(FAIL = element deletion strain)
Post-yield
Post
yield with necking
70
yield point
neck propagation
60
Strress MPa
50
40
necking starts
30
UTM1-39.62-1
20
UTM1-39.62-2
10
0
0
0.2
0.4
0.6
0.8
1.2
Strain mm/mm
1.4
1.6
MAT 24 Fail Limitations

When FAIL f(strain rate)
MAT 24 Rate Dependency

Cowper Symonds
LCSR
Capture model
independent
behavior
35
Tensile Stren
ngth (MPa)
Does not correlate

well with plastics
rate dependency
40
30
25
20
15
data
Cow per Symonds
10
E ring
Eyring
5
0
1.E-02
1.E-01
1.E+00
Strain Rate(/s)
1.E+01
1.E+02
MAT 24 LCSR
LCSR-Eyring
Eyring
Eyring Model
Yield stress v. log strain rate is linear
Best form for plastics
Fit yield stress v. log strain rate data to Eyring

equation
ti
Submit as table using LCSR
MAT 19 Brittle plastics
Modulus is rate dependent

Small strains to failure
Brittle
i l failure
f il
Failure strain decreases with increasing strain
rate
MAT 19 Methodology
Determine elastic limit at
quasi-static strain rate
Use elastic limit for vonvon
Mises yield
Define failure
failure stress v. strain rate
table
MAT 019 candidate materials

MAT_019
Launch CAE
Modeler
MAT 019 card

MAT_019
Set flags and model

features,
features
eg. Visco-plasticity
MAT 019 load curves

MAT_019
Default autofit of
MAT_019 model
Manual tuning of MAT_019

MAT 019 model
Drag and move yield

stress and fail stress
points. Software
calculates EMOD and
Tangent moduli
MAT 019 LC1:LC4

MAT_019
Save model file
Computed yield stress,

Youngs modulus,
tangent
g modulus and
failure stress
Material Model Library

You can also upload
externally created model
files
Model file is saved to

Material Model Library.
Model can be downloaded
or refit from here
MAT 89 Ductile-brittle
Non-linear behavior
Failure depends on strain
rate
Can handle ductile-brittle
transitions
Uses stress-strain curve
Limited to shell elements
MAT 89 Methodology
Submit stress-strain
curve
Submit EMOD
Submit rate dependency
via LCSR-Eyring
Submit failure strain v.
strain rate via LCFAIL
MAT 89 Workings
Internally decompose quasi stress-strain curve
Use EMOD for von Mises limit
Rest of the curve is elastic
elastic-plastic
plastic
Rate dependency via LCSR
Failure
F il
via
i LCFAIL
MAT 089 candidate materials

MAT_089
Launch CAE
Modeler
MAT 089 card

MAT_089
MAT 089 LCSS load curve

MAT_089
Default initial fit of

MAT_089 model.
Data is fit to yield
Adding post
post-yield
yield data
Note model overprediction at highest

strain
t i rate
t
Click to add post-yield
data. Drag and move
yield stress and fail stress
points.
Tuning rate dependency
Drag down yield stress

ratios to tune rate
dependency
Tuned MAT_089
MAT 089 model
Conclusions
Choice of material model depends on
material
test data
d
MAT89 is generically applicable

P
Proper
selection
l i = reasonable
bl model
d l
Simple improvements can add power
Validated
lid d models
d l represent baseline
b li
Models can be tuned for multi-axial loadings
Verification & Validation

Unit Element Test (easy)
Can be performed by analyst
Simple check on whether the model is sensible
Closed Loop Validation (moderately difficult)

Check if FEA returns the original material data
Open Loop Validation (difficult)

Comparison to alternate or multi-mode experiment
Closed Loop Validation
LS-DYNA
LS
DYNA Simulation
Comparison to experiment
60
50
limitation
LS-DYNA Simulation
Tensile Experiment
Stress (MPa)
40
MAT 24 Model
30
20
10
0
0
0.05
0.1
0.15
0.2
0.25
Strain (mm/mm)
0.3
What is CAE TestBench

TestBench
Open Loop Validation

Carefully designed Benchmark models
Not real-life
real life component
Simple multi-mode case
Well
W ll defined
d fi d boundary
b
d
conditions
diti
Load cases reproducible in virtual and real life
Trust methesenumbersaregood!
Static FEA TestBench Model

Cornell Bike Crank (Swanson)
Static loading
Complex geometry
Analytical solution exists
Well
W ll defined
d fi d load
l d case
Comparing simulation and test

Si l ti
ANSYS Simulation
DIC Experiment
In closing...
closing
Do not oversimplify
Use self consistent data
Understand
d
d your material
i l data
d

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Keynote:

Plastics & Simulation

Plastics and Simulation

strengthening the materials core of manufacturing enterprises

What makes plastics unique

strengthening the materials core of manufacturing enterprises

strengthening the materials core of manufacturing enterprises

strengthening the materials core of manufacturing enterprises

strengthening the materials core of manufacturing enterprises

strengthening the materials core of manufacturing enterprises

strengthening the materials core of manufacturing enterprises

strengthening the materials core of manufacturing enterprises

strengthening the materials core of manufacturing enterprises

Making test specimens

strengthening the materials core of manufacturing enterprises

strengthening the materials core of manufacturing enterprises

strengthening the materials core of manufacturing enterprises

strengthening the materials core of manufacturing enterprises

strengthening the materials core of manufacturing enterprises

strengthening the materials core of manufacturing enterprises

strengthening the materials core of manufacturing enterprises

strengthening the materials core of manufacturing enterprises

ANSYS CAE Modeler

strengthening the materials core of manufacturing enterprises

strengthening the materials core of manufacturing enterprises

strengthening the materials core of manufacturing enterprises

True Stre s s (M Paa)

The question of yield

strengthening the materials core of manufacturing enterprises

Determining onset of plasticity

strengthening the materials core of manufacturing enterprises

strengthening the materials core of manufacturing enterprises

strengthening the materials core of manufacturing enterprises

Elasto-plastic models for plastics

Engineering Stress ((MPa)

Engineering Strain (%)

strengthening the materials core of manufacturing enterprises

strengthening the materials core of manufacturing enterprises

Tangent modulus basis

strengthening the materials core of manufacturing enterprises

Secant modulus basis

strengthening the materials core of manufacturing enterprises

Fidelity to plastic point

strengthening the materials core of manufacturing enterprises

Fidelity to curve shape

strengthening the materials core of manufacturing enterprises

Post yield ductile behavior

strengthening the materials core of manufacturing enterprises

Digital Image Correlation(DIC)

strengthening the materials core of manufacturing enterprises

True Stress (MPa))

True Strain (unitless)

strengthening the materials core of manufacturing enterprises

strengthening the materials core of manufacturing enterprises

strengthening the materials core of manufacturing enterprises

strengthening the materials core of manufacturing enterprises

strengthening the materials core of manufacturing enterprises

strengthening the materials core of manufacturing enterprises

strengthening the materials core of manufacturing enterprises

Biaxial tension test

strengthening the materials core of manufacturing enterprises

strengthening the materials core of manufacturing enterprises

biaxial measured by cruciform

biaxial calculated from compression