Modelling Adhesively Bonded Joints with MAT252 and MAT_ADD_COHESIVE

Modelling of Adhesively Bonded Joints
with *MAT252 and *MAT_ADD_COHESIVE

for Practical Applications
F. Burbulla (Porsche AG), A. Matzenmiller (IfM, University of Kassel),
U. Kroll (IfM, University of Kassel)
10-European_LS-DYNA_Conference_2015.pptx
Burbulla, Matzenmiller, Kroll 2/32
Motivation
Modelling and FE-calculation of structural adhesive joints for the crash analysis are characterised by:
Reliable computation of the stresses in the adhesive layer
Description of the failure
Capture the strain rate dependent material properties
Efficiency with regard to the computation time (no influence on critical time step size)
Simple and unique identification of the material- and failure parameters
Outline
Non-associated elasto-viscoplastic material model (*MAT252 since LS-DYNA R7.1.1)
for rubber-toughened adhesive polymeres
Verification by means of basic tests
Modelling approaches for the adhesive joint
Formulation*MAT_ADD_COHESIVE (LS-DYNA R7.1.1) for interface elements (ELFORM 19 and 20)
Comparison of *MAT252 (TAPO-model) with *MAT169 (ARUP-model)
Validation by means of component-like specimens
Basic tests of adhesively bonded joints Tensional loading: = 0
35 Klebstoff: Betamate 1496 V
Rohrprobe
dk = 0,3 mm
30 23 C, 50% rel. Feuchte
Characterisation of the elastoplastic behaviour of the

-1
(d / dt = 0,001 s )
normal stress [MPa]

xy / 2x = 0
25
structural adhesive:
20
Axialspannung
15
Blunty glued steel tube specimen (DIN EN 14869-1) 10
0
0,00 0,05 0,10 0,15 0,20 0,25 0,30 0,35
strain [-]
Dehnung
Torsional loading: =
40
Klebstoff: Betamate 1496 V
Rohrprobe
35 dk = 0,3 mm
23 C, 50% rel. Feuchte
-1
(d / dt = 0,001 s )
30
[Schlimmer / Report of P676 FOSTA, 2007] xy / 2x =
shear stress [MPa]

25
Schubspannung
Torsion-, tension- and combined-loading-tests 20
as well as tests with loading and unloading 15
10
Tensional and torsional loadings are characterised: 5
0
Average testing speed: 2.0e-4 mm/s 0,0 0,2 0,4 0,6 0,8 1,0
shear strain [-]
Gleitung
Burbulla, Matzenmiller, Kroll TAPO-model 4/32
Yield functions of the TOUGHENED-ADHESIVE-POLYMERE-MODEL *MAT252
Yield conditions of the TOUGHENED-ADHESIVE-POLYMERE-MODEL (TAPO available since LS-DYNA R7.1.1):
In the domain of pressure, the elliptic yield function is No pressure tests available, then von MISES-yield condition
replaced by DRUCKER & PRAGER-criterion (FLG=1) (FLG=2) starting from vertex:
Conservative estimation of the

pressure-shear strength!
*MAT24
Consideration of the micro friction for pressure is performed by formative hardening:

[Yee and Pearson / J. Mat. Science, 1986]
Non-associated flow rule
Flow rule of the TOUGHENED-ADHESIVE-POLYMERE-MODEL (TAPO-model)
depends on elliptic plastic potential:
to reduce the plastic dilatation by means of an additional parameter .

Identification of parameter :
From uni-axial tension test with measurements
of axial and transversal strain
From tests of bluntly glued steel tube specimen

under tensile and combined tensile-shear loadings
inverse parameter identification with LS-OPT
Material hardening and strain rate dependency of the yield stress
Definition of the plastic arclength is based on then EUKLIDEAN norm:
Damaged hardening variable is introduced

because of thermodynamic consistency:
[Lemaitre: A Course on Damage Mechanics, 1992]
Standard (analytical approach):

Isotropic hardening stress depends on plastic deformation:
Rate dependent yield shear stress

of the plasticity model is according to
modified JOHNSON & COOK model:
. .
Identification of with testing rate dependent data*
*) M. Brede, IFAM, FhG Bremen, Report of P676, FOSTA, 2007

Material hardening and strain rate dependency of the yield stress
Definition of the plastic arclength is based on then EUKLIDEAN norm:
Damaged hardening variable is introduced

because of thermodynamic consistency:
[Lemaitre: A Course on Damage Mechanics, 1992]

Alternative (tabulated input):
Definition of the rate dependent yield shear stress
identically to *MAT24 with table formulation *TABLE

and curve formulation *CURVE is possible.
. .
Parameters of modified JOHNSON & COOK ansatz are not needed anymore.
Damage and failure of the adhesive layer
Development of the effective stress according to RABOTNOV in yield condition is performed by means
of the continuity
Evolution equation for damage Empirical approach for damage:
as a function of the plastification: [Lemaitre / J. Eng. Mater. Tech., 1985]
Fracture strain (shear resp. tensile fracture) depends on the loading.

Measure of the loading is the triaxiality , which influences the
fracture strain according to JOHNSON & COOK model:
Multiaxiality of the fracture strain

[Rice und Tracy / J. Mech. Phys. Solids, 1969]
Critical strain shall be proportional

to the failure strain :
Damage evolution takes place above the

defect inducing strain .
Damage and failure of the adhesive layer
Two damage models are available: DOPT=0 with turning point or DOPT=1 without turning point
DOPT=1 DOPT=0
Simple identification of the JOHNSON & COOK parameters:

pure shear
Blunty glued steel tube specimen Blunty glued steel tube specimen
lateral extension
with tensional loading with torsional loading constraint
Simulation of the basic tests for verification
Bluntly glued steel tube specimen (DIN EN 14869-1)

F
MT
modelling
[Schlimmer / Report of P676 FOSTA, 2007]
Discretization of adhesive layer is done by 1 solid element in direction of thickness

Average testing speed:
Identification of the material parameters for the elastic-plastic domain
including damage and failure is done by means of optimisation software LS-OPT
6 quasi-static tests of the bluntly glued steel tube specimen provide the data for the identification
Simulation of the basic tests
Comparisons of experiment* and simulation of the steel tube test:
stress
stress
displacement displacement
*) M. Schlimmer, C. Barthel, IfW, University of Kassel, Report of P676, FOSTA, 2007

Simulation of the basic tests cont.
Comparisons of experiment* and simulation of the steel tube test under pressure and torsion:
Press.
Press.
stress
stress
Static steel tube tests are suitable for the identification of the material parameters for plastic hardening
and damage
TAPO-model captures the basic phenomenological properties of the rubber-toughened adhesive
polymere
*) M. Schlimmer, C. Barthel, IfW, Universitt Kassel, Forschungsbericht zu P676, FOSTA, 2007
Simulation of the basic tests for verification
Dynamic tests of the butt jointed steel cylinder specimen*
adhesive modelling
F
Discretization of adhesive layer with 1 solid element in direction of thickness

Testing speeds at the specimen:
butt jointed cylinder specimen

Identification of the strain rate dependent material parameters bluntly glued steel tube specimen
regression yield stress
equivalent stress:
equivalent stress
equivalent shear strain rate:
determination of :
*) M. Brede, IFAM, FhG Bremen, Report of P676, FOSTA, 2007 equivalent strain rate
Modelling approaches of the adhesive joint
kinematics shell elements
middle plane
solid elements ELFORM 1 and 2 interface elements ELFORM 19 and 20
material models
3D-continuum compounded model
model accuracy
computational efficiency
Burbulla, Matzenmiller, Kroll Modelling approach 15/32
Formulation *MAT_ADD_COHESIVE for the interface element
with assumption of the state of strain:
strain rate
ELFORM=19
TAPO-continuum model resp. all classic solid models in LS-DYNA
back substitution for traction vector by means of CAUCHY-theorem
: adhesive layer with lateral extension constraint

Formulation *MAT_ADD_COHESIVE for the interface element
Comparison between simulations with solid and interface elements as well as the experiment*
by means of the steel tube test
Interf. Interf.
Interf. Interf.
Interf. Interf.
stress
stress
Advantages of the method:
Renewed parameter identification is not necessary.
Higher computational efficiency is achieded with interface element ELFORM=19 at quasi identical model
accuracy.
*) M. Schlimmer, C. Barthel, IfW, University of Kassel, Report of P676, FOSTA, 2007
*MAT252 versus *MAT169
Comparison between simulations with *MAT252 (TAPO-model) and *MAT169 (ARUP-model)
stress
stress
initial total
Number of material parameters: # of
*MAT added mass added mass
*MAT252 #15 versus *MAT169 #9 elements
[%] [%]
No dissipation at *MAT169
252 & MAT_ADD_COHESIVE 39609 2,33 2,37
Damage criterion:
*MAT252 strain based
169 39609 45,05 44,95
*MAT169 stress based
Added mass in computation of the complete vehicle structure
Burbulla, Matzenmiller, Kroll *MAT252 versus *MAT169 18/32
Validation of the TAPO-model by means of component-like
specimens
KS2-specimen Peel-Shear-Test T-intersection
LWF, Paderborn IfM, Kassel LWF, Paderborn
Burbulla, Matzenmiller, Kroll Validation 19/32
Validation by means of KS2-test rigid body F
FE-model of the KS2-specimen*
modelling
steel sheet
rigid body
combined tension-shear loadings

F symmetry plane
adhesive
specimen
specimen
mounting
steel sheet
adapter bolt mounting
90 60 30 0
*) O. Hahn, M. Wiling, LWF, University of Paderborn, Report of P676, FOSTA, 2007

Validation by means of KS2-specimen (nom. v = 10 mm/min)
Interf. Interf.
Interf. Interf.
specimen
force
force
specimen
mounting
adapter
90 60 30 0
Interf.
Interf. cross section of the KS2-specimen
Interf.
Interf.
interface with
dk = -1
force
force
interface with
dk = 0.3 mm
Validation by means of Peel-Shear-Test*
F
rigid body
adhesive joint
modelling
fixation by bolts
steel sheet
rigid clamping
F
1
adhesive
1
fixed steel cylinder
*) F. Burbulla, L. Schreiber, IfM, University of Kassel, 2010

Validation by means of Peel-Shear-Test*
fixed steel
cylinder
force
displacement
peeling shear
adhesive
teflon spacer
*) F. Burbulla, L. Schreiber, IfM, University of Kassel, 2010

Validation by means of T-intersection* (quasistatic)
2
spot weld
modelling 1
element size 2x2 mm
element size 5x5 mm

3
adhesive clamping
hydraulic cylinder
clamping
adhesive 1 2 3
*) O. Hahn, M. Wiling, LWF, University of Paderborn, Report of project P676, FOSTA, 2007
Validation by means of T-intersection* (quasistatic loading)
F
F
100% filled gap
loading in direction of lower bearer loading perpendicular to lower bearer
Interf. Interf.
filled gap
force
force
0% filled gap
*) A. Matzenmiller, F. Burbulla,: Kontinuumsmechanische Modellierung von
Stahlblechklebverbindungen fr die FE-Crashanalyse, 7th German LS-DYNA Forum, Bamberg, 2008
Validation by means of T-intersection* (dynamic loading)
initial velocity of impactor v=2.75 m/s
modelling
*) O. Hahn, M. Wiling, LWF, University of Paderborn, Report of project P676, FOSTA, 2007
Validation by means of T-intersection (dynamic loading)
front: back:
Interf. Interf.
force
displacement force displacement

Validation by means of T-intersection (dynamic loading)
loading in direction of the lower bearer

Interf.
with shortened adhesive bond
force
shortened adhesive bond
displacement

Future work
The TAPO-model captures the basic phenomenological material properties of the rubber-toughened adhesive
polymere Transfer to different classes of adhesives possible
Validation of TAPO-model and *MAT_ADD_COHESIVE by full vehicle simulations for different load cases will be
finished in sommer 2015
Damage initiation and fracture through *CURVES (function of triaxiality) resp. *TABLES (function of triaxiality
and strain rate) will be possible
Fracture shear strain will additionally be equipped with element size regularization
Extension of the HISTORY variables
Report in message file at beginning of damage - equivalent to spot weld formulation
Effective default values for all material parameters

Thank you for your attention!
Special thanks to Dr. Tobias Erhart (DYNAmore)
Acknowledgement:
The project has been financed from the
Bundesministeriums fr Wirtschaft und Technologie
through
Arbeitsgemeinschaft industrieller Forschungsvereinigungen Otto von Guericke e.V. (AIF)
for the program
Zukunftstechnologien fr kleine und mittlere Unternehmen (ZUTECH)
on behalf of the
Forschungsvereinigung Stahlanwendung e. V. (FOSTA).

Modelling Adhesively Bonded Joints with MAT252 and MAT_ADD_COHESIVE

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Modelling of Adhesively Bonded Joints

with *MAT252 and *MAT_ADD_COHESIVE

Characterisation of the elastoplastic behaviour of the

normal stress [MPa]

Blunty glued steel tube specimen (DIN EN 14869-1) 10

shear stress [MPa]

as well as tests with loading and unloading 15

Tensional and torsional loadings are characterised: 5

Conservative estimation of the

Consideration of the micro friction for pressure is performed by formative hardening:

depends on elliptic plastic potential:

to reduce the plastic dilatation by means of an additional parameter .

From tests of bluntly glued steel tube specimen

Damaged hardening variable is introduced

Standard (analytical approach):

Rate dependent yield shear stress

*) M. Brede, IFAM, FhG Bremen, Report of P676, FOSTA, 2007

Damaged hardening variable is introduced

identically to *MAT24 with table formulation *TABLE

Fracture strain (shear resp. tensile fracture) depends on the loading.

Multiaxiality of the fracture strain

Critical strain shall be proportional

Damage evolution takes place above the

Simple identification of the JOHNSON & COOK parameters:

Bluntly glued steel tube specimen (DIN EN 14869-1)

[Schlimmer / Report of P676 FOSTA, 2007]

Discretization of adhesive layer is done by 1 solid element in direction of thickness

Comparisons of experiment* and simulation of the steel tube test:

*) M. Schlimmer, C. Barthel, IfW, University of Kassel, Report of P676, FOSTA, 2007

Discretization of adhesive layer with 1 solid element in direction of thickness

butt jointed cylinder specimen

kinematics shell elements

solid elements ELFORM 1 and 2 interface elements ELFORM 19 and 20

3D-continuum compounded model

with assumption of the state of strain:

TAPO-continuum model resp. all classic solid models in LS-DYNA

back substitution for traction vector by means of CAUCHY-theorem

: adhesive layer with lateral extension constraint

KS2-specimen Peel-Shear-Test T-intersection

LWF, Paderborn IfM, Kassel LWF, Paderborn

combined tension-shear loadings

*) O. Hahn, M. Wiling, LWF, University of Paderborn, Report of P676, FOSTA, 2007

*) F. Burbulla, L. Schreiber, IfM, University of Kassel, 2010

*) F. Burbulla, L. Schreiber, IfM, University of Kassel, 2010

element size 5x5 mm

100% filled gap

loading in direction of lower bearer loading perpendicular to lower bearer

initial velocity of impactor v=2.75 m/s

displacement force displacement

loading in direction of the lower bearer

shortened adhesive bond

*) A. Matzenmiller, F. Burbulla,: Kontinuumsmechanische Modellierung von

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