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Anisotropic Micromechanical Creep Damage


Model for Composite Materials: A Reduced-Order
Approach

Article in International Journal for Multiscale Computational Engineering · January 2008


DOI: 10.1615/IntJMultCompEng.v6.i2.10

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International Journal for Multiscale Computational Engineering, 6(2)xxx–xxx(2008)

Anisotropic Micromechanical Creep Damage


Model for Composite Materials: A
Reduced-Order Approach

Erez Gal
Department of Structural Engineering, Ben Gurion University, Beer-Sheva, 84105, Israel

Jacob Fish
Multiscale Science and Engineering Center, Rensselaer Polytechnic Institute, Troy, NY 12180, USA

ABSTRACT

An anisotropic micromechanical model aimed at characterizing the response of composite


material to creep is presented. The constitutive model of microconstituents is based on the
Kachanov-Robotnov creep damage model for isotropic materials. An anisotropy of the model
is introduced through homogenization, which derives macroscopic properties from microme-
chanical properties of microconstituents. A reduced-order micromechanical model is formu-
lated to substantially reduce (up to several orders of magnitude) the number of unknowns in
the microscopic problem compared to the direct homogenization approach. The reduced-order
model is based on the reduced-order homogenization with eigen-strains, which describes the
inelastic part of the microscopic displacement field by means of eigen-deformations. An adap-
tive algorithm has been devised to evaluate the time step needed to ensure solution accuracy.
Numerical studies are presented to demonstrate the efficiency of the model.

KEYWORDS

xxx

*Address all correspondence to fishj@rpi.edu

c 2008 by Begell House, Inc.


1543-1649/08/$35.00 ° 1
2 GAL AND FISH

1. INTRODUCTION terms of a small number of unknowns and thus re-


duce the computational cost significantly compared
Creep is characterized by the formation of perma- to the direct homogenization approach.
nent strains and material degradation due to appli- Since creep is a time-dependent process, it is nec-
cation of load over extended periods of time. For essary to control the time step to ensure solution
certain materials, such as metals, this phenomenon accuracy. An adaptive time-integration algorithm,
occurs when material reaches about 30% of its boil- which evaluates the nearly optimal time step size, is
ing temperature [1,2]. In other materials, such as proposed. The primary objective of the article is to
concrete [3], creep occurs at room temperatures. develop an analysis and design framework for creep
Kachanov [4] used a continuum damage mechan- of heterogeneous solids. The reduced-order creep
ics model to evaluate material degradation due to model has been seamlessly integrated in ABAQUS.
creep. Based on Kachanov’s model, Robotnov [5] Numerical studies of the heterogeneous model are
developed a creep model for the uniaxial state of conducted on several industrial applications.
stress. Leckie and Hayhurst [6], among others,
extended the model to the multiaxial case. Vari-
ous variants of the Kachanov-Robotnov model have 2. THE DAMAGE CREEP MODEL
been widely used (e.g., see [7–13]) to analyze the This section describes an isotropic creep damage
response of structures made of isotropic materials. model of microconstituents: the anisotropic macro-
The manuscript extends the Kachanov-Robotnov scopic creep model obtained via reduced-order ho-
model to anisotropic heterogeneous materials. mogenization and the adaptive time scheme.
In the present article, the material degrada-
tion of each constituent in the micromechani-
cal representation of the material is modeled via 2.1 The Creep Damage Constitutive Equations
an isotropic Kachanov-Robotnov model [6]. The In the following, we describe a phenomenological
continuum damage model represents the damage creep model of Kachanov [4], which postulates the
state using damage parameters and evaluates the rate of creep strain and damage as
creep strain in each microconstituent. The over-
all anisotropic macroscopic strain vector is obtained ε̇c = f (σ, T, ω)
using reduced-order homogenization [14]. (1)
ω̇ = g (σ, T, ω)
Homogenization provides macroscopic material
properties from the properties of microconstituents where σ is stress, T is the temperature, and ω is the
(e.g., see [15,16]). The direct homogenization damage parameter describing material degradation;
method, which accounts for detailed microstruc- f and g are the creep strain rate and the material
ture, has been successfully used in various indus- degradation rate, respectively. For the uniaxial state
trial applications for linear problems. On the other of stress, Robotnov [5] proposed the following ex-
hand, nonlinear homogenization (e.g., see [16–30]) pressions:
requires a repetitive solution of the unit cell prob-
lem, and therefore a reduced-order approach is crit- ασn βσp
ε̇c = m ω̇ = q (2)
ical to reduce the computational cost. In the present (1 − ω) (1 − ω)
article the reduced-order model developed by Os-
Equation (2) is known as the Kachanov-Robotnov
kay and Fish [14], which generalizes the transfor-
equation, where α, β, n, m, p, and q are temperature-
mation field analysis [31–34], is applied to solve the
dependent material parameters. For the multiaxial
micromechanical problem. The method exploits an
state of stress, Leckie and Hayhurst [6] proposed the
additive decomposition of strains into elastic and
following relations:
inelastic contributions and expresses the inelastic
part in terms of eigen-deformations, which include −n
eigen-strains and eigen-separations. The resulting ε̇cij = 32 ασ∗ij S n−1 (1 − ω) (3a)
stress field is residual-free, i.e., it satisfies equilib-
rium equations in the unit cell for arbitrary eigen- βσpr
deformation. The eigen-strains can be discretized in ω̇ = q (3b)
(1 + q) (1 − ω)

International Journal for Multiscale Computational Engineering


ANISTROPIC MICROMECHANICAL CREEP DAMAGE MODEL 3

where the subscripts ij denote spatial components; and ũi is the displacement induced by creep within
α, β, p, q, and n are the material parameters, σr is the microconstituents and at their interfaces. Fol-
the creep rupture stress, σ∗ij is the deviatoric stress, lowing [14], ũi is expressed in terms of the eigen-
and S is equivalent von Mises stress. strains, µij , and the eigen-separations, δi , as
Considering that the rupture stress is a function
of the effective stress and the maximum principal Z
stress, σ1 , Eq. (3b) can be rewritten as ũi (x, y, t) = hph
ikl (y, ŷ) µkl (x, ŷ, t) dŷ
p θ
[γσ1 + (1 − γ) σvm ] Z
ω̇ = β q (4)
(1 + q) (1 − ω) + hint
im (y, ŷ) δm (x, ŷ, t) dŷ (6)
where γ is a material constant introduced to reflect S

the influence of the multiaxial stress states on the


where hph int
ikl and him are phase and interface damage
rupture. Equation (4) was used by [8].
influence functions, respectively (for more details,
The reduced-order model, or so-called spatial up-
see [14]).
scaling, is described in the next section.
The unit cell equilibrium equation is given by

2.2 Spatial Up-Scaling


σij,yj = 0
The spatial up-scaling adopted in this article is h i (7)
based on the mathematical homogenization theory σij = Lijkl (y) ε̄kl (x, t) + u1(k,yl ) − µkl
with eigen-deformations [14], which has its roots in
various eigen-strain-based formulations [17–20,35– where σij is stress and µkl is eigen-strain computed
37]. In the mathematical homogenization theory by time integration of ε̇cij :
with eigen-deformations, the unit cell is subdivided
into phase and interface partitions. The kinematics Z Z
3 ∗ n−1 −n
of the unit cell is fully described in terms of these µij = ε̇cij dt = ασ S (1 − ω) dt (8)
eigen-deformations, which are the unknowns in the 2 ij
t t
unit cell problem. Thus the computational complex-
ity of the unit cell problem is significantly reduced Following [14], the partitioned fields are given as
in comparison to the direct computational homog-
enization method, where the nodal values of the Z
(γ) 3 ∗(γ) (γ)n−1 ³ ´−n
discretized unit cell displacement field are the un- µij = ασij S 1 − ω(γ) dt
knowns in the unit cell problem. This reduction 2
t " #
of the computational complexity is, in particular, X (9)
K
pronounced for nonlinear problems, such as creep, σ(γ) (γ)
= L A ε̄ + (P (ηγ)
− δ I)µ (η)

where a unit cell has to be solved repeatedly at ev- η

ery Gauss point of the macroproblem and at every


and the overall constitutive relation is
load/time increment.
The reduced-order model is based on the approx-
imation of the second term in the two-scale asymp- γ=1
X
totic expansion, u1i , which represents the unit cell σ̄ (x, t) = L̄ε̄ (x, t) + M̄(γ) µ(γ) (x, t) (10)
displacement field within the unit cell as (see also n
[14,17–19])
where A(γ) , P(ηγ) , and M̄(γ) are coefficient tensors
precomputed prior to nonlinear analysis [14].
u1i (x, y, t) = Hikl (y) ε̄kl (x, t) + ũi (x, y, t) (5) The spatial multiscale model is schematically
shown in Fig. 1. It features an intermediate (or
where Hikl is a periodic function in the microscale meso-) scale (Fig. 1(b)) at the scale of the mi-
coordinate y; ε̄kl is the macroscopic strain vector, crophases and their interfaces. The link between the
which is a function of the macroscale coordinate x; mesoscale and the microscale is established at the

Volume 6, Number 2, 2008


4 GAL AND FISH

(a) microscale
model (b) mesoscale (c) macroscale
model model

FIGURE 1. Microscale, mesoscale, and macroscale models

(m)
preprocessing stage (i.e., prior to the macroanaly- where ∆ωt+(∆t/2) is the damage increment related
sis). The mesoscale model is then linked (two-way to the state of damage at the time t + ∆t/2. In case
coupled) with the macroscale problem (Fig. 1(c)) the difference between the values obtained by Eqs.
during the nonlinear solution process, rather than (11) and (12) is larger than the user-defined toler-
with the microscale problem (Fig. 1(a)), as in the di- ance, the time step is reduced by a factor of 2. This
rect homogenization method (e.g., [15,16]). The ac- process is repeated until convergence is achieved.
curacy of the model is controlled by increasing or de-
creasing the number of phase and/or interface par-
titions. The computational cost is closely related to 3. NUMERICAL EXAMPLES
the number of partitions, i.e., each additional phase
This section describes verification and computa-
partition increases the number of unknowns by six,
tional feasibility studies of the proposed multiscale
while each additional interface partition increases
model.
the number of unknowns by three.

2.3 Adaptive Integration Scheme 3.1 Verification Studies

An adaptive scheme is proposed where the initial Consider an isotropic bar subjected to uniform ten-
time step is selected and subsequently adjusted to sile stress values of 150, 175, 200, 225, and 250 MPa.
preserve desired solution accuracy. The value of the Material architecture considered in this study is de-
creep damage parameter is selected to control the picted in Fig. 2. The reduced-order model consists
time step. Alternatively, or in addition, creep strain of one matrix partition, one fiber partition, and zero
invariants could have been used for this purpose. interface partitions. The material properties used
The phase damage at time step t+∆t is computed
as
(m) (m) (m)
ωt+∆t = ωt + ∆t∆ωt (11)
(m)
where ωt+∆t is the damage parameter at the end of
(m)
the time step, ωt is the damage at the beginning
(m)
of the time step, and ∆ωt is the current damage
increment related to the state of damage at the be-
ginning of the time step. This value is compared to
the value obtained in the following expression:

(m) (m) ∆t ³ (m) (m)


´
ωt+∆t = ωt + ∆ωt + ∆ωt+ ∆t (12) FIGURE 2. Unit cell finite element (FE) model
2 2

International Journal for Multiscale Computational Engineering


ANISTROPIC MICROMECHANICAL CREEP DAMAGE MODEL 5

for creep and damage calculations are as follows: Ef 3.2 Analysis of the Industrial Components
= 89.5e3; νf = 0.3; αf = 5.623e-18; nf = 5.911; βf =
1.114e-15; qf = 4.8; pf = 5.416; Em = 89.5e3; νm = Two composite structural components, the compos-
0.3; αf = 5.623e-18; nf = 5.911; βf = 1.114e-15; qf = ite tailcone exhaust and a stiffened composite panel,
4.8; and pf = 5.416, where subscripts m and f denote were chosen for demonstration of multiscale capa-
matrix and fiber material, respectively. bilities.

The variation of the damage parameter and the 3.2.1 The Composite Tailcone Exhaust
creep strain versus time as obtained for the different
values of stress levels are shown in Figs. 3 and 4, re- The composite tailcone is subjected to pressure on
spectively. In Figs. 3 and 4, the y-axis represents the its upper surface, as shown in Fig. 5. The tailcone
value of the damage parameter (0 for undamaged attachment is modeled using springs. To be noted
and 1 for the totally damaged material) and creep are the four cut-outs in the tailcone that give rise to
strain, respectively, while the x-axis represents time stress concentrations and damage initiation. Owing
in hours. These results are in perfect agreement with to symmetry, only one-eighth of the component, as
the results obtained by [8]. shown in Fig. 6, have been modeled.

1
0.9 S=150 S=175
0.8 S=200 S=225
S=250
Damage Parameter

0.7
0.6
0.5
0.4
0.3
0.2
0.1
0
0 200 400 600 800 1000 1200 1400 1600
Time (Hr)

FIGURE 3. Evolution of creep damage in uniaxial loading

1.8

1.6 150 175


200 225
1.4 250
1.2
Creep Strain

0.8

0.6

0.4

0.2

0
0 200 400 600 800 1000 1200 1400 1600
Time (Hr)

FIGURE 4. Evolution of creep strain in uniaxial loading

Volume 6, Number 2, 2008


6 GAL AND FISH

applied The microstructure is depicted in Fig. 2. The


pressure
reduced-order model consists of one matrix parti-
tion, one fiber partition, and zero interface parti-
tions. The rescaled material properties were se-
lected as follows: Ef = 410e3; νf = 0.127; αf =
5.623e-18; nf = 5.911; βf = 1.114e-15; qf = 4.8; pf =
5.416; Em = 210e3; νm = 0.127; αf = 5.623e-18; nf =
5.911; βf = 1.114e-15; qf = 4.8; and pf = 5.416, where
subscripts m and f denote matrix and fiber materi-
als, respectively.

cutouts springs The macroscopic finite element mesh consists of


3627 composite shell elements, as shown in Fig. 6.
FIGURE 5. Tail cone exhaust Each composite shell element consists of three lay-
ers, with a total number of nine Gauss points
through the thickness. The top and bottom layers
are reinforced in the peripheral direction, while the
middle layer has fibers aligned in the longitudinal
direction.

The distribution of the damage parameter is de-


picted in Fig. 7. The white color represents elements
where the damage exceeded the critical value. The
red color represents a high-damage parameter (but
less than 1), while the blue color represents a mod-
est damage state. The damage initiated in the vicin-
ity of the cut-outs and propagated along the attach-
ments.

The multiscale creep model was integrated in


FIGURE 6. FE model of one-eighth of the tailcone ex- ABAQUS and ran for about 7 hours on a 32-bit Intel
haust Pentium M 1400-Hz single-processor computer.

Zoom

FIGURE 7. Damage distribution in the tailcone exhaust

International Journal for Multiscale Computational Engineering


ANISTROPIC MICROMECHANICAL CREEP DAMAGE MODEL 7

3.2.2 The Stiffened Composite Panel


Figure 8 depicts a stiffened composite panel sub-
jected to axial displacements representing deforma-
tion of an aircraft wing.
The geometry, boundary conditions (Fig. 8), and
composite material layout are as follows: panel ra-
dius R = 938 mm; panel length l = 660 mm; arc
length la = 680 mm; number of stiffeners n = 5; lay-
out of the skin [0; -45; 45; 90]; layout of each stiffener
[-45; 45; 0; 0]; ply thickness t = 0.5–1.0 mm; and stiff-
ener height h = 20 mm.
The rescaled material properties are as follows:
Ef = 410e3; νf = 0.127; αf = 5.623e-18; nf = 5.911;
βf = 1.114e-15; qf = 4.8; pf = 5.416; Em = 210e3; νm
= 0.127; αf = 5.623e-18; nf = 5.911; βf = 1.114e-15;
qf = 4.8; and pf = 5.416, where subscripts m and f
denote matrix and fiber materials, respectively.
FIGURE 9. Stiffened panel finite element model
The macroscopic finite element mesh consists of
4320 composite shell elements, as shown in Fig. 9.
Each composite shell element consists of four layers,
with a total number of 12 Gauss points per element.
The distribution of the damage parameter is de-
picted in Fig. 10. The white color represents
elements where the damage exceeded the critical
value. Elements that were totally damaged initiated
creep damage. It can be seen that the damage initi-

Axial displacement
fixed edge

45º 0º
S.S. edge

S.S. edge

90º
Skin
L= 660mm

FIGURE 10. Damage within the elements


1

ated along the edges in the vicinity of the stiffeners


and propagated along the edges between the stiff-
Stiffeners eners of the panel. This multiscale simulation ran
for 19 hours on a 32-bit Intel Pentium M 1400-Hz
single-processor computer.

fixed edge
4. CONCLUDING REMARKS
La=680mm
An anisotropic multiscale creep damage model for
FIGURE 8. Stiffened composite panel geometry and composite materials and structures was developed
boundary conditions and verified in a model problem, and feasibility

Volume 6, Number 2, 2008


8 GAL AND FISH

studies have been conducted on two structural com- V weldments. Int. J. Pressure Vessels Piping.
ponents. 82:137–144, 2005.
The model is based on the reduced-order homog- 10. Hayhurst, D. R., Goodall, I. W., Hayhurst, R. J.,
enization with eigen-deformations. The reduced- and Dean, D. W., Lifetime predictions for high-
order model substantially reduces the number of temperature low alloy ferritic steel weldments.
unknowns in the unit cell problem. The application J. Strain Anal. 40:675–701, 2005.
of the reduced-order model was found to be feasi-
11. Mustata, R., and Hayhurst, D. R., Creep con-
ble on two problems of reasonable size utilizing a
stitutive equations for a 0. 5Cr 0.5 Mo 0.25 V
single-processor machine.
ferritic steel in the temperature range 565◦ C–
In our future work, the model will calibrated to
675◦ C. Int. J. Pressure Vessel Piping. 82:363–372,
test data. A two-step calibration procedure consist-
2005.
ing of calibration of elastic properties and calibra-
tion of damage model parameters to creep test data 12. Hyde, T. H., and Sun, W., Elastic-creep behav-
will be pursued. ior of a three-material plate subjected to a bi-
axial stress states. Mater. Sci. Eng. A 417:74–181,
2006.
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Volume 6, Number 2, 2008

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