III.

Engineering Plasticity

References
1. Forging simulation (M. S. Joun, 2013, Jinseam Media)
2. Advanced solid mechanics and finite element method
(M. S. Joun, 2009, Jinseam Media)

Mechanical quantities and their correlation

2-2

Displacement ui ui ( x j , t )
Strain-displacement relation

du
Velocity vi i
dt

1
ij (ui , j u j ,i )
2
Strain ij

Strain rate-velocity
relation

Strain rate ij

1
ij (vi , j v j ,i )
2

Temperature T
Acceleration ai

dvi
dt

Temperature,
0th order Effective strain,
tensor Effective
(scalar) strainrate,
Energy, Power

Damage D
Microstructure M

Stress ij

Thermodynamics
First law
Second law

Constitutive law
Isothermal ij ij ( ij , ij , D, M ), ect.
Nonisothermal ij ij (T , ij , ij , ), ect.

Newton s law of motion

Equation of motion ij , j f i vi
Equation of equilibrium ij , j f i 0

Virtual work principle

Virtual work-rate principle
Minimum total potential theorem
Hamilton s principle
etc.

ij ij

Coupled analysis

1th order Displacement,

tensor Velocity,
(vector) Force

2th order Stress,

tensor Strain,
(Dyadic) Strainrate

1. Tensile test

2-4

Tensile test
Tensile test

Definition of

U
Y

Predictions of tensile test

L0

t ln

, e
Lf

and e
P
A0

e : engineering
t : true

ln 1 e

Engineering
L0 strain

Y Yield
P

Eng. stress

P P A0
Necking
N
A A0 A

F Fracture
Lf
P

e
e
e 1
eY : Yield strength
A0 L0
U : Tensile strength
max 100 : %, Elongatio

eu

max

Engineering stress-strain curve

2-5

True strain and True stress

L f L0
Initial area A0

L0

Current area A

L0 L0 L0 2

L0 (n 2) L0 (n 1)

True stress
e

P
A0

Lf
P
P A
0 e
e (1 e )
True stress
Af A0 Af
L0

Engineering
stress

L0 L0
L0 (n 1)
n

i 1

True strain
e

Engineering
Engineering strain
strain

L0

t ln

Lf
L0

ln 1 e True
Truestrain
strain

L0 (i 1)

Lf
L0

dL
L

ln 0

ln
1

L0
L
L
0
0

ln(1 e )

ln

Lf

Linear elastic and Hookes law

1

Hooke law (Between O and P)

Between O and Y

t E t , E

e t , e t

x E x , xx E xx

P
U

e e

Poissons ratio
F
Final

Initial

E
O

eu

Modulus of elasticity,
Youngs modulus

max

Initial

Final

lat

t
long
a

Plastic deformation and true stress-strain curve

1 Between Y and F

Specimen

Yield Point

e t , e t

True

F
N

F
Y

Necking Point

Engineering

Fracture Point

Y Y
e

u
t u ln(1 eu ) e

L0

P
A0

t lnln
1 Lfe ln 1

t
e

L0
t e (1P e ) P A0
t

A
A0 A

P Lf

e 1 e

Stress vector
1 Internal force and stress vector
0
A0

(n )

T t (n)

n cos i sin j

i
j

Stress vector

P 0 A 0

P 0 A 0i

A
A 0
sin

P
0 sin i
A

0 sin
0 cos sin nt

0 sin 2 nn

t (n ) 0 sin 2 n 0 cos sin t

P 0 A 0

30

45

60

90

n
3
0
2

2
0
2

=0

1
0
2

o
1
0
4

3
0
4

Normal stress and shear stress

1 Stress

component
0

N = P sin

A0

P 0 A 0

T = P cos
A

A0
sin

Normal stress

nn

Shear stress

nt

N P
sin 2 0 sin 2
A A0

T P
cos sin 0 cos sin
A A0

t (n ) 0 sin 2 n 0 cos sin t nn n nt t

t
90
n

n 0
nt 0

n
3
4

n 0

o
nt

30

45

60

1
2

n 0
nt 0

n 0

=0

1
4

n 0

1
2

nt 0

3
0
4

nt

3
0
4

2. Force - Stress

Stress vector
2

Internal force

External force
F
F

F
F

F
F

Stress vector
(n )

T t

(n )

Ti t

(n )

(n )
i

F
lim
A0 A
Fi
lim
A0 A

t(-n)

t(n)

t ( n) = t (n)
ti( n ) ti(n )

Stress component
2D

y ( yy )
yx ( yx )

xy ( xy )

Point

t (i) xxi xy j
t (j) yxi yy j

x ( xx )

Plane stress

xx ( x ) xy ( xy )
( ) ( )
yy
y
yx yx

0
0

0
0

A point in 2D= Square

3D

z e3

z face

zz
zy
yz

zx

xz
x

xx
e1

t (ei ) i1e1 i 2e2 i 3e3

t (jei ) ij

y face
xy
yx yy y e2

x face

A point in 3D = Cubic

xx xy xz
ij yx yy yz
zx zy zz

Equation of equilibrium
F
Infinitesimal
area

F3

F1
x

x
y

yy ( x , y y)

xx ( x , y)

0;

0;

0;

y A xy ( x x , y)

yy ( x , y)

Axis-symmetric)

x ( x x, y )
xx
( x , y)
x
xx
xx ( x , y )
x
yx ( x , y)
x

2D(Plane stress, Plane strain,

yx ( x , y )

yx

xy

F 4

2D

yx ( x , y y )

xx yx

0
x
y
yx yy

0
x
y

xy yx

Body force neglected

3D xx

yx

zx
fx 0
x
y
z
xy yy zy

fy 0
x
y
z
xz yz zz

fz 0
x
y
z

xy yx , yz zy , zx xz

Cauchy's formula
2D

width 1

yy
yx
xy

l cos

xx

n cos i sin j n x i n y j

xx

yx

3D

yy

Fx

0 ; t x( n ) xx nx yx ny

Fy

0 ; t y( n ) xy nx yy ny

t x( n ) xx xy nx
( n )
n

t
yy y
y yx

(n )

ij

xy

l sin

t (n )

length l

t x(n ) xx
(n )
t y yx
t z(n ) zx

xy
yy
zy

xz nx

Cauchys formula

zz nz

ti( n ) ji n j

yz n y

Coordinate transformation
Pure shear

2D
y

xx

xy
xx

xy
l cos

yy

yx

3D
y

xx xx cos 2 yy sin 2 2 xy sin cos

x
2
2
length l xy ( xx yy )cos sin xy (cos sin )
l sin

xx xy cos

yx yy sin

sin xx xy cos

cos yx yy sin

sin
cos

Transformation
matrix

x
x
z

Tip cos( xi , x p )

' T T

Two transformation matrixes = 2nd order of tensor

xx xy xz Txx Txy Txz xx xy xz Txx Tyx Tzx

T
T
T

T
T
T
yx yy yz yx yy yz yx yy yz xy yy zy
T T T T T T
zx zy zz zx zy zz zx zy zz xz yz zz

T T

Similarity
transformation

!!! Eigenvalues of '

and are identical !!!

Principal stress
t

Cauchys formula

t
t

(n )
x
(n )
y
(n )
z

xx

yx
zx

xy
yy
zy

xz nx

(n )

yz n y

(n )

zz nz

ij

N n

Principal direction

(n )

n
n 1

Eigenvalue problem

xx

yx
zx

xy

Principal
stress

xz nx 0

yy
yz ny 0
zy
zz nz 0

xx

yx
zx

xy
yy
zy

xz nx

nx

yz n y n y


zz nz
nz

Principal stresses and stress invariants

Solving eigenvalue problem
Characteristic
equation

xx
xy
xz
Principal
3
2
stresses
yx
yy
yz I1 I 2 I 3 0
zx
zy
zz
1 , 2 , 3
Stress Invariants
I1 xx yy zz 1 2 3
I 2 xx yy yy zz zz xx

I 3 xx yy zz 2 xy yz zx xx

xx

yx
zx

xy
yy
zy

xz nx

xy

nx

yz n y i n y


zz nz
nz

yz

2
yz

yy

2
zx

2
zx

1 2 2 3 3 1

zz

Principal
directions

n n(i )

xy

1 2 3

' T T

Similarity
transformation

n(i ) n( j ) 0 (i j )

Effective stress
Mean stress m
and hydrostatic pressure p

Deviatoric stress tensor ij

m ii / 3 I1 / 3 p

Invariant J 2 and effective stress

xx m
xy
xz

ij yx
yy m
yz

zy
zz m
zx

I12 1
J 2 I 2 (1 2 )2 ( 2 3 )2 ( 3 1)2
3 6

3J 2

2
2
3
1
2
2
2
2

6(

ij ij
xx
yy
yy
zz
zz
xx
xy
yz
zx

2
2

1
2
2
2
1 2 2 3 3 1

z
zz

zx
xz

xx

zy

xy yx

x face

yz

yy

y face
y

z face

Equivalent

Tensile test

Example 2D
Given stress

Eigenvalue problem

20

n1
80
80 60 n1

60
20
n
60

2
n2

60
0
20

60

80

80 60 0
60 20 0

0 0 10

Solving the problem

(80 )(20 ) 3600 0

1 117.1, 2 17.1

60
80 117.1
n1 0
i ) 1 117.1

n
20 117.1 2 0
60

37.1n1 60n2 0
ii ) 1 17.1 60n2 37.1n2 0
17.1

(1)

n (1)

n1
0.85

0.53
n2

117.1
2

z 10
zx zx 0

31.7 o

p tan 1

31.7
0.85

0.53

0.53
31.7o
0.85

Example 2D
Solving the problem Mohrs circle

20

y 20

103.9

60

80

x 80

2P

3.88

x xy cos

yx y sin

xy 60

sin x xy cos

cos yx y sin

R (80 20)2 / 4 602

1 c R 117.1
2 c R 17.1

sin
cos

17.1

117.1

c (80 20) / 2 50

40

R 67.1

40.0

80

31.7 o

2 xy
1
1
p tan (
)
2
x y
p tan 1

0.53
31.7o
0.85

31.7o
0.85

0.53

Example 2D
Invariants
I1 xx yy zz 1 2 3
I 2 xx yy yy zz zz xx 2 xy 2 yz 2 zx

z 10
zx zx 0

1 2 2 3 3 1
I3 xx yy zz 2 xy yz zx xx 2 yz yy 2 zx zz 2 xy

y 20

R 67.1

1 2 3

80

2P

a
20

I1 80 20 10 110

60

80

x 80

I 2 80 20 20 10 10 80 60 60 1000
I3 80 20 10 2 80 0 80 0 20 0 10 60 60 20000

17.1
117.1
2

31.7 o

I1 117.1 17.1 10 110

I 2 117.1 (17.1) (17.1) 10 10 117.1 1000
I 3 117.1 (17.1) 10 20000

103.9
b

40.0
40

3.88

I1 103.9 3.9 10 110

I 2 103.9 (3.9) (3.9) 10 10 103.9 40 40 1000
I3 103.9 (3.9) 10 2 40 0 103.9 0 (3.9) 0 10 40 40 20000

xy 60

Example 2D
Effective stress
m p

20 80 10 110

37
3
3

0
43 60
ij 60 17
0

0
27
0

1
2
2
2
80 20 20 10 10 80 6(602 0 0)

15100

1
2
2
2
117.1 (17.1) 17.1 10 10 117.1

15100

3. Deformation Strain,
Strain Rate

2-24

Displacement and velocity

Displacement

u x x, y xy
u y x, y

4 5
5

Velocity field

1 2
x y 1

Velocity

1'

7
3 (1, 1) 1

7 2

u x 1,1 1
u y 1,1 1

Effective strain-rate

Deformation = displacement rigid-body motion

Strain
Plane strain
Example : Dam, strip rolling

(1 yy )y E

ux , u y f ( x, y), uz 0

xy

y
O

(1 xx )x

After

xy 2 xy deformation

xx
ij yx
0

xy
yy

0
0

ux , u y f ( x, y), uz 0

Before
deformation

Strain in 3D
xx xy xz

ij yx yy yz

zx zy zz
xy yx , yz zy , zx xz

xx lim

O' C' - OC

yy lim

O' E' - OE

c 0

OC

c 0

xy 2 zy

OE

E' O' C'

Strain-displacement relationship

ij ui
u
xx x
x
u y
yy
y
u z
zz
z

relationship
1 u x u y
xy (

)
2 y
x
1 u y u z
yz (

)
2 z
y
1 u z u x
zx (

)
2 x
z

1 ui u j
ij (

)
2 x j xi

Meaning of strain
ux
u
lim x |x fixed ?
y y 0 y
ux |x fixed
ux ( x, y y)

y
x

ux ( x, y)

tan

ux |x fixed

y
tan , 1

Strain rate, Strain rate-velocity relationship

Strain rate ij
xx

ij yx

zx

xy xz

yy yz
zy zz

ij

v y
vx
vz
xx
, yy
, zz
x
y
z

d ij

dt

ij ij dt , ij

Strain rate-velocity relationship

1 vi v j

)
2 x j x j

, ij ij t

Example

t 10.000 (s)

100.0mm

t 10.001 (s)

101.0mm

1.0
0.01
100.0
xx
0.01

xx
xx

1
10.0
0.001
s

xx xx t

1 vx v y
1 v y vz
1 v v
xy (

), yz (

), zx ( z x )
2 y x
2 z y
2 x z

Principle strain and effective strain

Eigenvalue problem
xx

yx
zx

xy xz nx
nx

yy yz ny ny
nz
zy zz nz

k ni ni( k )

3 L1 2 L2 L3 0
1 , 2 , 3

( k ) (l )
i
i

Principal strain

L1 ii

3
3

Volumetric strain

0 (i j )

Principal axes are

perpendicular.

Mean strain and deviatoric strain

v m

xx m

ij yx

zx

xy
yy m
zy

xz

yz
zz m

Effective strain
1

2
2
2
2
2 2

ij ij
1
2
2
3
3
1

3
3

Principal strain rate and effective strain rate

Eigenvalue problem
xx

yx
zx

xy xz nx
nx

yy yz ny ny
nz
zy zz nz

ij ij 0

k ni ni( k )

L1 L2 L3 0

ni( k ) ni(l ) 0 (i j )

1 , 2 , 3

Principal strain rate

Mean value and deviatoric tensor

L1 ii
v m
3
3

xx m

ij yx

zx

Volumetric strain rate

xy
yy m
zy

xz

yz
zz m

Effective strain rate and effective strain

1

2
2
2
2
2 2

ij ij
1
2
2
3
3
1

3
3
1

dt
0

ij

ij dt
0

Principal axes are

perpendicular.

4. Yield criterion and

deformation

Yield criterion
Tresca yield criterion

Huber-von Mises yield criterion

f J2 k 2

1
ij ij k 2 0,

f max k 0

1
2
2
2
1 2 2 3 3 1 Y
2

2
2
1
2
xx yy yy zz zz xx 6 xy 2 yz 2 zx 2 Y

Tensile test

1 0 2
2 Y
max 1

True

Tresca

Engineering

F Tensile test

Torsion test

3 0

von Mises 12 1 2 22 Y 2 0

1 , 2 3 0, Y

eu

max

max min
2

Yield surface in 3D

Yield locus in 2D

Y
2

Normality and flow rule

Druckers postulate:
Normality

f 0

Strain rate tensor should be perpendicular to yield surface

f

, ij

f
f
ij
or ij
ij
ij

Normality

xx yy
zz xy yz zx

xx yy zz xy yz zx

For the material obeying von Mises yield criterion

f
1
1
1
f

pq pq k 2 ( ip jq pq pq ip iq ) ( ij ij ) ij

1
ij ij 2
2
2
f k 2

pq

ij

ij

ij

f
f
ij , ij
ij
ij

3
2

ij

ij

2
3

ij ij , 3J 2
ij ij
3
2

Yield surface :
Yield surface
f ( ij ) 0

22

23

2
2
ij
ij
3
3

Y
2
kl kl

ij

Flow stress
Zero in rigid zone.
Numerical problem occurs.

13
12

33

11

ij f
Normality of strain rate to
yield surface

Strain hardening
4Strain hardening
Plastic deformation accompanies dislocation.
Dislocation is a kind of defect, slip or twist between atoms.
Dislocation prevents generation of new dislocation =

Strain hardening

Strain hardening models

F
True

Engineering

Y Y ( )

u
t u ln(1 eu ) e

Isotropic hardening

Kinematic hardening

Idealization of deformation and flow stress

Deformation

FS at the room temperature

ij ij ij

Yo 1 , K n , Yo K n
b

Yo : ,
Initial yield stress
Initial yield stress

ij p :
Plastic strain rate ( Plastic strain- rate)

d : ( Difference strain- rat

Difference strain rate
ij

Elastoplastic
(Elastoplastic) : ij d ij e
.
ij e : Elastic
Elastic strain rate
Rigid-plastic

(Rigid-plastic) : ij d 0

K : ,
Strength coefficient
Strength coefficient
n : ,
Strain
hardening exponent
Strain hardening
exponent

FS at the elevated temperature

C n m , C m

Flow stress model

= Constant
= Y e ,
= Y

Perfectly plastic

= Y p ,

Elastoplastic
Rigid-plastic

Rigid-viscoplastic

= Y p , p , T Rigid-thermoviscoplastic

n : Strain hardening exponent

m : Rate dependency
C : Hot strength coefficient

Generalized Hookes law for isotropic material

y

zz

yy

Assumption : Small deformation.

Principle of superposition.

yy

xx

xx

z
xx

ii 0

E
2(1 )
Shear modulus
of elasticity

1
Poissons ratio

xx

zz
yy

yy
E

xx zz v yy

zz

zz
E

xx yy v zz

xy yz zx 0 xy yz zx 0 xy yz zx 0

1 xx

xx

xx

yy zz v xx

ij Gij
G

1 v xx

yy zz xx xx
E

xy

xx v yy zz

yy yy v xx zz

zz zz v xx yy
E

1
1
1
xy , yx yz , zx zx
G
G
G

xx

Generalized
Hookes law for
isotropic material

Effect of thermal expansion

Thermal expansion
Problem

Simple length
of curve

T L
T / L T

Coefficient of
thermal
expansion

yy
zz
xx E xx

1
v T
xx
zz
yy E yy

1
zz zz v xx yy T

1
1
1
xy xy , yx yz , zx zx
G
G
G

C
L

Generalized
Hookes law
for isotropic
material with
thermal
expansion
considered
779MPa

-18MPa

5. Equation of heat
conduction, Friction and
Summary of mechanics

Heat transfer in solid

5 Law of heat conduction
Fouriers law of heat conduction
2D/3D

One-dimensional

qx

Coefficient of
thermal
conduction

Law of heat convection

qc hq (T T )
Heat transfer
coefficient

x x
T T T

Law of heat radiation

qr (T 4 Tq 4 )
Stefan-Boltzmann constant

Boundary Value Problem of heat transfer

5 Equation of heat conduction for solid
( qx x qx )yz ( q y y q y )zx

( qz z qz )xy qg xyz c

qx
x, etc.
x
q
T
qx x qx x x k

x
x x
qx x qx

T
k
x x

T
k
y y

T
k
z z

T
xyz
t
Thermal
capacity

qg c
t

q g (0.9 1.0)

Boundary conditions

T T on ST

k T n kT,i ni (T Tq ) hq (T Tq ) on S q
4

Indicial notation

T,i ni
i

T
ni
xi

Law of friction and law of mass conservation

Law of friction special boundary condition
Hybrid friction

Law of Coulomb friction

t n g (vt ) on SC when n m ' k

t m ' k g (vt ) on SC when n m ' k

t n g (vt ) n on SC
Coefficient of Coulomb friction

Equality applies when slip occurs.

Law of constant shear friction

t mk g (vt ) mk on SC

g (vt )

tan 1

(vt vt )
a

Friction factor

Mass conservation
Incompressible

Compressible

ii ui ,i 0

( vi ),i

ii vi ,i 0

Indicial notation

Contact surface

0
t
qi ,i

Coulomb
Improved Coulomb

mk

Hybrid

mk

qi
xi

Constant shear stress

Summary of mechanics
Detailed law

Group

Requirement on equilibrium

Newtons
law of motion

Law of mass
conservation

Equation of equilibrium

Equation of heat conduction

Law of energy conservation

Continuity equation

Hookes law
Plastic flow rule

Constitutive law
Fouriers law of heat conduction

Geometry of
deformation
Boundary
Conditions

F , maM,
ma
F
IM I
ii

Equation of motion

Law of energy
conservation

Equations

Strain-displacement

ii

Explanation
i

j i , j fi 0,f i j0,
ij ji j i
ji, j
i

j i , j fjii , j vfii vi
k , i , ki ,qi g qcgt c
,i
k , i , i qg c t t, j v j
, j v j
v 0k , i , i qg c

0
vi , i i , i 0
t
1

i j 2
vi ij, i k k i j 0, i j 1 i j
E
t
2 1
i j i j 1
ij
kk i j
3i j

qi k , i E
2
i j
i j
3
1
i j ui , j u j , i
2
1qi k , i
i j vi , j v j , i
2
ui ui , vi vi ,
n
ti ij ji nj 1tui ,i , jqi
u j, ik , i qi
2
i, i

1
vi , j v j , i
2

Strain rate-velocity

i j

Essential

ui ui , vi vi ,

Natural

ti j i n j ti , qi k , i qi
n

Navier-Cauchy equation
Navier-Stokes equation
For solid
For fluid
Incompressible

k k i j
Compressible

Mechanical quantities and their correlation

2-42

Displacement ui ui ( x j , t )
Strain-displacement relation

du
Velocity vi i
dt

1
ij (ui , j u j ,i )
2
Strain ij

Strain rate-velocity
relation

Strain rate ij

1
ij (vi , j v j ,i )
2

Temperature T
Acceleration ai

dvi
dt

Temperature,
0th order Effective strain,
tensor Effective
(scalar) strainrate,
Energy, Power

Damage D
Microstructure M

Stress ij

Thermodynamics
First law
Second law

Constitutive law
Isothermal ij ij ( ij , ij , D, M ), ect.
Nonisothermal ij ij (T , ij , ij , ), ect.

Newton s law of motion

Equation of motion ij , j f i vi
Equation of equilibrium ij , j f i 0

Virtual work principle

Virtual work-rate principle
Minimum total potential theorem
Hamilton s principle
etc.

ij ij

Coupled analysis

1th order Displacement,

tensor Velocity,
(vector) Force

2th order Stress,

tensor Strain,
(Dyadic) Strainrate