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Finite Element Simulation Using Abaqus: Internship On

The document discusses simulations conducted in Abaqus of various mechanical tests including tensile testing, Erichsen cupping testing, and three-point bending testing of titanium alloy specimens to analyze the material properties and behavior of both the base metal and weld joints. The simulations aimed to evaluate properties like yield strength, formability, and springback ability. The results from the tensile test showed the weld joint withstanding higher stresses than the base metal before failure.

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ranjithkraj
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287 views24 pages

Finite Element Simulation Using Abaqus: Internship On

The document discusses simulations conducted in Abaqus of various mechanical tests including tensile testing, Erichsen cupping testing, and three-point bending testing of titanium alloy specimens to analyze the material properties and behavior of both the base metal and weld joints. The simulations aimed to evaluate properties like yield strength, formability, and springback ability. The results from the tensile test showed the weld joint withstanding higher stresses than the base metal before failure.

Uploaded by

ranjithkraj
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Internship

On

Finite element simulation using Abaqus


Undergone
at

National Institute of Technology, Trichy

Under the guidance of

Dr. N. Siva Shanmugam


Assistant Professor
Department of Mechanical Engineering
National Institute of Technology
Trichy
Contents
 Introduction to ABAQUS

 Problem Statements

 Material Properties

 Tensile Test

 Erichsen Cupping Test

 Three point Bend Test

 Conclusion
Introduction to ABAQUS

ABAQUS/Standard : It works on Implicit procedures, solving a coupled system of


equations at each increment by forming global stiffness matrix. It is most suitable
for static problems.

ABAQUS/Explicit : It is preferred for dynamic problems where time play an


important role.

ABAQUS/CAE : It is interactive graphical user interface environment includes both


ABAQUS/standard and ABAQUS/Explicit
Introduction to ABAQUS
 Abaqus analysis generally consists of below three steps:

• Pre-Processing
• Simulation
• Post-Processing

 Unit System in ABAQUS


Problem statements

 Tensile Test

 Erichsen Cupping Test

 Three point Bending Test


Material Properties
 All the three tests are conducted on the titanium welded
specimens. The material properties of the both parent
metal and weld bead metal are given below.
Properties of Ti-6Al-4V Specimen

Material Section Young’s modulus (GPa) Density (g/cc) Yield stress


(MPa)

Ti-6Al-4V Parent metal 120 4.47 943

Ti-6Al-4V (Filler) Weld metal 200 4.47 880

 In ABAQUS the True stress vs True strain material data is


required for defining the material models.
Material Properties
True stress vs True strain
1400

1200

1000
Stress (MPa)

800
Parent material
Weld material
600

400

200

0
0 0.05 0.1 0.15 0.2 0.25

Strain (MPa)
Tensile Test
 Specimen is prepared according to ASTM E8/E8M
(Standard test method for testing metallic materials)

All dimensions are in mm


Tensile Test
 Model is prepared with four node linear Tetrahedron
elements(C3D4).

Total number of nodes: 4549


Total number of elements: 16799

 One end of the specimen is fixed in all directions


(U1=U2=U3=UR1=UR2=UR3=0) while the other end is
allowed to move in longitudinal direction only.

 The free end is applied with a displacement of 15 mm in


longitudinal direction.
Tensile Test
 Results and Discussion
• Necking is observed at the parent metal section as the
stress value reaches 1070 MPa
• The contour plots for variation of stress and
Displacement across the model are shown below.
Tensile Test
• Displacement magnitude contour plot across the full model
Tensile Test
Force vs Displacement
50000

45000

40000

35000

30000

25000
Force

combine ( 'Disp vs Time','RF vs Time' )


20000

15000

10000

5000

0
0 71 41 15 .9 68 42 17 92 67 43 19 94 69 44 .2 95 .7 45 .2 96
0 . 1 . 2 . 2 3 . 4. 5. 5. 6. 7 . 8. 8. 9. 10 . 1 1 1 1 . 1 2 13 . 14 1 4 .

Displacement
Erichsen Cupping Test
 It is used to evaluate the formability of the material

 The test consist of a sheet metal placed between blank


holder and die and pressing the test piece into the die by
means of a penetrator having a spherical head, until the
end point is reached.

 Rupture commence when a crack appears through the full


thickness of the test piece.

 Generally, rupture is accompanied by drop in the force and


this is considered as the end point of the test. The depth of
the penetration is noted.
Erichsen Cupping Test
 The rectangular specimen is prepared of size 70x70x2 mm.

 The punch has the diameter of 25mm and the die has
30mm and 40 mm as internal and external radius
respectively.

 Blank is modelled with 3D deformable shell where as the


punch and die are modelled as rigid.

 Surface to surface frictional contact property is defined


with frictional co-efficient of 0.15.

 Punch is constrained in such a way that it is allowed to


move in vertical direction only.
Erichsen Cupping Test
 The rigid die is completely constrained in all directions

 For simulation displacement of 6 mm is given to the punch


in vertical direction.

 Results and Discussion:

At the step time of 0.068 sec the maximum displacement


of 5.1 mm is reached. At the same time stress value reaches
the maximum value represents the commencement of
rupture.
Erichsen Cupping Test

Deformed shape at the step time 0.608sec


Erichsen Cupping Test
Vonmises stress vs Punch displacement
1400

1200

1000
Stress(Mpa)

800

At node
600 3281

400

200

0
0 1 2 3 4 5 6 7

Displacement(mm)
Three point Bending Test
 The test is used for brittle materials to evaluate the flexural
strength and flexural modulus.

 For ductile materials it is used to determine the bending


ability of the material without any rupture.

 The specimen is loaded in the fashion of simply supported


beam and bent to the maximum possible angle without any
rupture.

 In this work the spring back action of titanium specimen is


simulated.
Three point Bending Test

 The weld specimen of rectangular section with 25.6 mm


width and 200 mm length and thickness of 2 mm is
modelled as 3D deformable body with hexahedral type
elements(C3D8R).

 The two supports of 10mm radius and actuator with 10


mm nose radius are modelled with the same C3D8R
elements
Three point Bending Test

 The final assembled test set up is shown below


Three point Bending Test
 The distance between the supports is maintained at
100mm

 The surface to surface contact formulation is given with


frictional co-efficient of 0.15.

 The simulation involves both loading and discharge steps.

 The actuator is allowed to move in vertically downward


direction with a distance of 27.8 mm during the loading
step and is taken back during discharge step.
Three point Bending Test
 Results and Discussion:

• Due to maximum displacement given during the


loading step, the specimen undergoes maximum
bending angle of 39°.

• At the end of the discharge step it is found that the


titanium specimen undergoes a spring back angle of
22° which proves the good elastic strength of titanium.
Three point Bending Test
Conclusion
 Tensile test results show that the specimen yields at the
parent metal section rather than the welded section of the
specimen, this proves the strength of welded joint.

 According to Erichsen cupping test, crack is supposed to


appear at the peak load followed by drop in the load. So
the maximum stress induced of 1278.9MPa corresponding
to displacement of 5.1mm was found.

 Three point bending test results prove the good spring back
ability of titanium welded joint.

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