Porous-ductile fracture in thermo-elasto-plastic solids with contact applications

Abstract

Industrial forming processes depend on several physical effects, including large deformation thermomechanical damage, localized near the contact zone of the forming tools. The main challenge in this process relies on the detailed knowledge of the desired thermoplastic effects at finite strains and the undesired initiation of macro-cracks. For the numerical solution of this problem, a regularized sharp crack surface in the framework of a phase-field approach is combined here with a modified, thermomechanical Gurson–Tvergaard–Needelman GTN-type plasticity model, such that we obtain a thermodynamically consistent framework. This allows to adapt this highly complex multi-field model using variationally consistent Mortar contact formulations in a straightforward manner. Eventually, the proposed approach is tested on complex three-dimensional geometries, emanating from industrial relevant forming processes.