School of Aerospace, Mechanical and Manufacturing

Engineering

MIET2012
Computational Engineering 2
Finite Element Methods (FEM) stream
_____________________________________________________________________________________

Example problems
Three point bending

In this exercise you will become familiar with

• using ductile, shear, and Müschenborn-Sonne forming limit diagram (MSFLD) damage initiation
criteria to study the initiation of failure due to three different mechanisms
• modeling progressive failure of components using damage evolution and element removal

Rigid Punch
R = 50

250
Double-chambered
Thickness = 2.5 aluminium extrusion

68
95 500

Rigid Support
R = 25
350
250 Thickness = 1.0
25
Figure 1: Schematic diagram of the aluminium extrusion model

Geometry
The three-point bending configuration is shown in Figure 1. The overall dimensions of the aluminum
extrusion are L=500 mm, W=95 mm, and H=68 mm. The thickness of the sheet is 2.5 mm.

Materials
The material used in this study is an extruded aluminum alloy EN AW-7108 T6. This material behaves in
an elastic-plastic manner and can undergo damage due to either one or a combination of the following
damage mechanisms: nucleation and coalescence of voids, shear band formation, and necking instability.

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Material properties are given in Appendix:

Boundary conditions and loading

The three-point bending configuration consists of the aluminum extrusion supported on two rigid cylinders
and loaded in the transverse direction by another rigid cylinder. All the degrees of freedom at the
reference node associated with the rigid support are constrained

A velocity boundary condition in the global 2-direction is specified at the reference node of the rigid punch
with all the remaining degrees of freedom constrained. The velocity boundary condition at the rigid punch
applies the load in the three-point bending simulation is given in the appendix.

Note: Complex time- or frequency-dependent boundary conditions, loads, and predefined fields can be specified by referring to
an amplitude curve in the prescribed condition definition. For this exercise, the prescribed magnitude of the velocity boundary
condition can vary with time during a step according to an amplitude definition.
Abaqus/CAE Usage: Amplitude module: Create Amplitude: Choose Tabular for the type and
continue, then enter the amplitude data.

Interactions
A contact pair interaction is defined between the rigid punch and the node-based surface of the aluminum
extrusion component. A general contact interaction is defined between the rigid cylinders forming the
support and the element-based surface of the aluminum extrusion component. In addition, self-contact is
defined between the element-based surfaces of the extruded component. A friction coefficient of 0.05 is
used for the contact between the rigid cylinders and the extruded component, and a value of 0.15 is used
for the self-contact.

Analysis steps
The analysis consists of one explicit dynamic step and the total simulation time is 0.050 s. The analyses
consider geometric nonlinearity and use automatic time incrementation using element-by-element stable
time increment estimates.

Output requests
The field output request includes the following quantities: displacement, stress, strain, element status, and
damage initiation criteria variables. The history output request consists of displacement, velocity,
acceleration, and reaction force at the reference point of the top rigid cylinder. Energy output variables are
requested for the entire model.

Adopted from
1. Hooputra, H., Gese, H., Dell, H., and Werner, H. (2004), A comprehensive failure model for crashworthiness simulation of aluminium
extrusions, International Journal of Crashworthiness, 9:5, 449-464
2. Abaqus example Problems Manual, 6.9 © Dassault Systèmes, 2009
.

Prepared by:

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Dr. Toh Yen Pang
September 2010

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Appendix
Material data and velocity curve

Density = 2.7E-9
Young’s Modulus = 70E3
Poission’s Ratio = 0.33
Plasticity behaviour
Yield Plastic
Stress Strain
311 0
316.64 0.003437
324.52 0.008593
335.2 0.016327
348.96 0.027928
365.52 0.045329
383.7 0.071431
401.65 0.11058
418.21 0.16931
434.74 0.25741
455.35 0.38955
485.16 0.58775
529.75 0.88507
596.64 1.331
696.98 2
696.98 2.1

Damage for Ductile Metal

Fracture Stress Strain

Strain Triaxiality Rate
33.238 -3.333 0.0001
33.238 -0.33333 0.0001
23.381 -0.26667 0.0001
16.447 -0.2 0.0001
11.57 -0.13333 0.0001
8.1394 -0.06667 0.0001
5.7268 0 0.0001
4.0303 0.066667 0.0001
2.8377 0.13333 0.0001
2 0.2 0.0001
1.4124 0.26667 0.0001
1.0013 0.33333 0.0001
0.7155 0.4 0.0001
0.5192 0.46667 0.0001
0.3878 0.53333 0.0001
0.3048 0.6 0.0001
0.26 0.66667 0.0001
0.24758 0.7301 0.0001
0.30283 0.85097 0.0001
0.61953 1.0237 0.0001
1.9018 1.2435 0.0001
7.5608 1.5058 0.0001

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 7.5608 3.3333 0.0001
33.238 -3.3333 0.001
33.238 -0.33333 0.001
23.381 -0.26667 0.001
16.447 -0.2 0.001
11.57 -0.13333 0.001
8.1394 -0.06667 0.001
5.7268 0 0.001
4.0303 0.066667 0.001
2.8377 0.13333 0.001
2 0.2 0.001
1.4124 0.26667 0.001
1.0013 0.33333 0.001
0.7155 0.4 0.001
0.5192 0.46667 0.001
0.3878 0.53333 0.001
0.3048 0.6 0.001
0.26 0.66667 0.001
0.24758 0.7301 0.001
0.30283 0.85097 0.001
0.61953 1.0237 0.001
1.9018 1.2435 0.001
7.5608 1.5058 0.001
7.5608 3.3333 0.001
84.132 -3.3333 250
84.132 -0.33333 250
47.327 -0.26667 250
26.621 -0.2 250
14.974 -0.13333 250
8.4238 -0.06667 250
4.7393 0 250
2.6675 0.066667 250
1.5034 0.13333 250
0.85084 0.2 250
0.48779 0.26667 250
0.29076 0.33333 250
0.19263 0.4 250
0.16006 0.46667 250
0.18195 0.53333 250
0.26576 0.6 250
0.44001 0.66667 250
0.74341 0.7301 250
2.0883 0.85097 250
9.2599 1.0237 250
61.718 1.2435 250
593.67 1.5058 250
593.67 3.3333 250
84.132 -3.3333 1000
84.132 -0.33333 1000
47.327 -0.26667 1000
26.621 -0.2 1000
14.974 -0.13333 1000
8.4238 -0.06667 1000
4.7393 0 1000
2.6675 0.066667 1000

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 1.5034 0.13333 1000
0.85084 0.2 1000
0.48779 0.26667 1000
0.29076 0.33333 1000
0.19263 0.4 1000
0.16006 0.46667 1000
0.18195 0.53333 1000
0.26576 0.6 1000
0.44001 0.66667 1000
0.74341 0.7301 1000
2.0883 0.85097 1000
9.2599 1.0237 1000
61.718 1.2435 1000
593.67 1.5058 1000
593.67 3.3333 1000
Damage evaluation, displacement at failure = 0.1

MSFLD Damage data

Major Minor Plastic
Principal Principal Strain
Strain Strain Rate
0.2037 -0.10185 0
0.1659 -0.06913 0
0.14548 -0.04849 0
0.12454 -0.03114 0
0.11234 -0.01872 0
0.10013 -0.00834 0
0.088206 0 0
0.092471 0.007113 0
0.10346 0.015916 0
0.1203 0.027762 0
0.1422 0.043753 0
0.16194 0.062283 0
0.1859 0.0858 0
0.20756 0.11176 0
0.22714 0.13978 0
0.24487 0.16952 0
0.25572 0.19671 0
0.26551 0.22466 0
0.27437 0.25327 0
0.28241 0.28241 0
Damage evaluation, displacement at failure = 0.1

Shear Damage Data

Shear
Fracture Stress Strain
Strain Ratio Rate
0.2761 -10 0.0001
0.2761 1.4236 0.0001
0.2613 1.4625 0.0001
0.253 1.5013 0.0001
0.251 1.5401 0.0001
0.2551 1.5789 0.0001

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 0.2656 1.6177 0.0001
0.2825 1.6566 0.0001
0.3065 1.6954 0.0001
0.3379 1.7342 0.0001
0.3778 1.773 0.0001
0.4269 1.8118 0.0001
0.4865 1.8506 0.0001
0.5581 1.8895 0.0001
0.6435 1.9283 0.0001
0.7448 1.9671 0.0001
0.8644 2.0059 0.0001
1.0053 2.0447 0.0001
1.171 2.0835 0.0001
1.3655 2.1224 0.0001
1.5937 2.1612 0.0001
1.8611 2.2 0.0001
1.8611 10 0.0001
0.2761 -10 0.001
0.2761 1.4236 0.001
0.2613 1.4625 0.001
0.253 1.5013 0.001
0.251 1.5401 0.001
0.2551 1.5789 0.001
0.2656 1.6177 0.001
0.2825 1.6566 0.001
0.3065 1.6954 0.001
0.3379 1.7342 0.001
0.3778 1.773 0.001
0.4269 1.8118 0.001
0.4865 1.8506 0.001
0.5581 1.8895 0.001
0.6435 1.9283 0.001
0.7448 1.9671 0.001
0.8644 2.0059 0.001
1.0053 2.0447 0.001
1.171 2.0835 0.001
1.3655 2.1224 0.001
1.5937 2.1612 0.001
1.8611 2.2 0.001
1.8611 10 0.001
0.33382 -10 250
0.33382 1.4236 250
0.33361 1.4625 250
0.33552 1.5013 250
0.33955 1.5401 250
0.34572 1.5789 250
0.35409 1.6177 250
0.36473 1.6566 250
0.37765 1.6954 250
0.39297 1.7342 250
0.41077 1.773 250
0.43117 1.8118 250
0.4543 1.8506 250
0.48038 1.8895 250
0.50943 1.9283 250

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 0.54171 1.9671 250
0.57742 2.0059 250
0.61678 2.0447 250
0.66005 2.0835 250
0.70762 2.1224 250
0.75956 2.1612 250
0.8163 2.2 250
0.8163 10 250
0.33382 -10 1000
0.33382 1.4236 1000
0.33361 1.4625 1000
0.33552 1.5013 1000
0.33955 1.5401 1000
0.34572 1.5789 1000
0.35409 1.6177 1000
0.36473 1.6566 1000
0.37765 1.6954 1000
0.39297 1.7342 1000
0.41077 1.773 1000
0.43117 1.8118 1000
0.4543 1.8506 1000
0.48038 1.8895 1000
0.50943 1.9283 1000
0.54171 1.9671 1000
0.57742 2.0059 1000
0.61678 2.0447 1000
0.66005 2.0835 1000
0.70762 2.1224 1000
0.75956 2.1612 1000
0.8163 2.2 1000
0.8163 10 1000
Damage evaluation, displacement at failure = 0.1

Arbitrary time variations of velocity

Time Amplitude
0 0
0.000125 79.97266
0.00025 159.822
0.000375 239.4249
0.0005 318.6586
0.000625 397.4011
0.00075 475.5307
0.000875 552.927
0.001 629.4708
0.001125 705.0441
0.00125 779.5302
0.001375 852.8143
0.0015 924.7834
0.001625 995.3265
0.00175 1064.335
0.001875 1131.702
0.002 1197.325
0.002125 1261.101
0.00225 1322.932

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0.002375 1382.724
0.0025 1440.384
0.002625 1495.823
0.00275 1548.955
0.002875 1599.699
0.003 1647.976
0.003125 1693.712
0.00325 1736.837
0.003375 1777.284
0.0035 1814.99
0.003625 1849.897
0.00375 1881.952
0.003875 1911.105
0.004 1937.312
0.004125 1960.531
0.00425 1980.728
0.004375 1997.87
0.0045 2011.932
0.004625 2022.891
0.00475 2030.731
0.004875 2035.44
0.005 2037.01
1 2037.01

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