Modified Johnson Cook Research Articles

Method of Finite Element Model Updating for Identifying the Parameters of Modified Johnson–Cook Constitutive Equation

Method of Finite Element Model Updating for Identifying the Parameters of Modified Johnson–Cook Constitutive Equation

Internal cooling system effects to heat transfer and tool wear in turning operations of titanium alloys Ti6Al4V

Internal cooling systems are essential for turning operations to improve the efficiency and quality of the machining process. In this paper, application of the virtual machining system is developed to analyze the effects of internal cooling systems on heat transfer and tool wear in turning operations of titanium alloys Ti6Al4V. The cutting forces as well as cutting temperature along machining paths are simulated in the virtual machining system to predict and analyze the effects of internal cooling system to the heat transfer and tool wear during turning operations. The coolant flow inside the internal cooling channels of a rotating cutting tool is simulated using computational fluid dynamics. Next, utilizing the modified Johnson–Cook model, the cutting temperature during turning operations is determined. The finite element method is employed to predict tool wear by applying the Takeyama–Murata analytical method. To validate the study, experimental works are implemented using turning machine tool. The cutting settings during experimental works are feed rate of 0.3 mm/rev, depth of cut of 2 mm, and cutting speed of 75 m/min. Thus, using the proposed virtual machining system, the performance of internal cooling system can be enhanced to increase cutting tool life and surface quality of machined parts in turning operations.

Pore collapse, shear bands, and hotspots using atomistics-consistent continuum models for RDX (1,3,5-trinitro-1,3,5-triazinane): Comparison with molecular dynamics calculations

Shock-induced energy localization is a crucial mechanism for determining shock sensitivity of energetic materials (EMs). Hotspots, i.e., localized areas of elevated temperature, arise when shocks interact with defects (cracks, pores, and interfaces) in the EM microstructure. The ignition and growth of hotspots in a shocked energetic material contribute to rapid chemical reactions that can couple with the passing shock wave, potentially leading to a self-sustained detonation wave. Predictive models for shock-to-detonation transition must correctly capture hotspot dynamics, which demands high-fidelity material models for meso-scale calculations. In this work, we deploy atomistics-guided material models for the energetic crystal RDX (1,3,5-trinitro-1,3,5-triazinane) and perform tandem continuum and all-atom molecular dynamics (MD) simulations. The computational setup for the continuum and MD simulations are nearly identical. The material models used for the calculations are derived from MD data, particularly the equations of state, rate-dependent Johnson–Cook strength model, and pressure-dependent shear modulus and melting temperature. We show that a modified Johnson–Cook model that accounts for shear-induced localization at the pore surface is necessary to represent well—relative to MD as the ground truth—the inelastic response of the crystal under a range of shock conditions. A head-to-head comparison of continuum and atomistic calculations across several metrics of pore collapse and energy deposition demonstrates that the continuum calculations are in good overall agreement with MD. Therefore, this work provides improved RDX material models to perform physically accurate meso-scale simulations, to enhance understanding of hot spot formation, and to use meso-scale hot spot data to inform macro-scale shock simulations.

Continuum models for meso-scale simulations of HMX (1,3,5,7-tetranitro-1,3,5,7-tetrazocane) guided by molecular dynamics: Pore collapse, shear bands, and hotspot temperature

Meso-scale calculations of energy localization and initiation in energetic material microstructures must capture the deformation and collapse of pores and high-temperature shear bands, which lead to hotspots. Because chemical reaction rates depend sensitively on temperature, predictive continuum models need to get the pore-collapse dynamics and resulting hotspot temperatures right; this imposes stringent demands on the fidelity of thermophysical model forms and parameters and on the numerical methods employed to perform high-resolution meso-scale calculations. Here, continuum material models for β-HMX are examined in the context of shock-induced pore collapse, treating predictions from all-atom molecular dynamics (MD) simulations as ground truth. Using atomistics-consistent material properties, we show that the currently available strength models for HMX fail to correctly capture pore collapse and hotspot temperatures. Insights from MD are then employed to advance a Modified Johnson–Cook (M-JC) strength model, which is shown to capture key aspects of the physics of shock-induced localization in HMX. The study culminates in a MD-guided strength model for β-HMX that produces continuum pore-collapse results in better alignment on several aspects with those predicted by MD, including pore-collapse mechanism and rate, shear-band formation in the collapse zone, and temperature, strain, and stress fields in the hotspot zone and the surrounding material. The resulting MD-informed/MD-determined M-JC model should improve the fidelity of meso-scale simulations to predict the detonation initiation of HMX-based energetic materials in microstructure-aware multi-scale frameworks.

Dynamic mechanical properties and uni-axial constitutive model of S30408 stainless steel

This paper investigates its mechanical properties at different strain rates and the uni-axial constitutive model of S30408 (S30408 known as 1.4301 in EN10088:1, 304 in ASTM standard) stainless steel. Firstly, the tensile and compressive mechanical properties of S30408 stainless steel were tested at four strain rates (0.001 s−1, 1000 s−1, 3000 s−1, 5000 s−1) by performing quasi-static tests as well as split Hopkinson tension bar (SHTB) and split Hopkinson pressure bar (SHPB) tests. Based on the tests, the stress-strain curves of S30408 stainless steel under tensile and compressive conditions at different strain rates were obtained. The results show that S30408 stainless steel revealed a significant strain rate strengthening effect, and there were some differences in the mechanical properties of S30408 stainless steel in tension and compression under different strain rates. Then based on these test results, a modified Johnson–Cook model was established under tensile and compression conditions. The accuracy of the proposed modified Johnson-Cook model was verified by the finite element software LS-DYNA. The modified model can provide a reference for the study of mechanical properties and computational simulation of S30408 stainless steel under high strain rate conditions such as impact and blast load.

Modified constitutive models and cutting finite element simulation of Ti-6Al-4V alloy at cryogenic

Mastering the high strain characteristics at cryogenics and constructing an accurate constitutive model are critical for establishing a cryogenic cutting simulation of Ti-6Al-4V alloy. The traditional constitutive model is inadequate for accounting for high and cryogenic conditions. In this paper, cryogenic split Hopkinson pressure bar (SHPB) experiments are conducted, specifically for Ti-6Al-4V alloy, to develop a modified Johnson–Cook (J–C) constitutive model that incorporates the cryogenic effect. A coupled two-dimensional orthogonal finite element simulation involving temperature displacement was conducted for the cryogenic cutting of Ti-6Al-4V alloy. This simulation was performed using ABAQUS, based on a modified J–C constitutive model subroutine. It was observed that the smallest discrepancy between the simulation results and the data from ice-fixed milling experiments was just 2.12%. The modified J–C constitutive model is more adept at simulating the chip morphology under cryogenic conditions. It was also found that cryogenic machining enhances the distribution of temperature and stress within the chip. For every 5°C reduction in processing temperature, the tool temperature diminishes by more than 2%.

A thermo-mechanical fully coupled model for high-speed machining of Ti6Al4V

PurposeThis study aims to further refine the model, explore the influence of cutting parameters on the machining process, and apply it to practical engineering to improve the efficiency and quality of titanium alloy machining.Design/methodology/approachThis paper establishes a comprehensive thermo-mechanical fully coupled orthogonal cutting model. This paper aims to couple the modified Johnson–Cook constitutive model, damage model and contact model to construct a two-dimensional orthogonal cutting thermo-mechanical coupling model for high-speed cutting of Ti6Al4V. The model considers the evolution of microstructures such as plastic deformation, grain dislocation rearrangement, dynamic recrystallization, as well as stress softening and hardening occurring continuously in Ti6Al4V metal during high-speed cutting. Additionally, the model incorporates friction and contact between the tool and the workpiece. It can be used to predict parameters such as cutting process, cutting force, temperature distribution, stress and strain in titanium alloy machining. The study establishes the model and implements corresponding functions by writing Abaqus VUMAT and VFRICTION subroutines.FindingsThe use of different material constitutive models can significantly impact the prediction of the cutting process. Some models may more accurately describe the mechanical behavior of the material, thus providing more reliable prediction results, while other models may exhibit larger deviations. Compared to the Tanh model, the proposed model achieves a maximum improvement of 8.9% in the prediction of cutting force and a maximum improvement of 20.9% in the prediction of chip morphology parameters. Compared to experiments, the proposed model achieves a minimum prediction error of 2.8% for average cutting force and a minimum error of 0.57% for sawtooth parameters. This study provides a comprehensive theoretical foundation and practical guidance for orthogonal cutting of titanium alloys. The model not only helps engineers and researchers better understand various phenomena in the cutting process but also serves as an important reference for optimizing cutting processes.Originality/valueThe originality of this research is guaranteed, as it has not been previously published in any journal or publication.Peer reviewThe peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-05-2024-0168/

Dynamic deformation and fracture surface investigation of rolled homogenous armor steel through Charpy impact testing

The amount of energy that can be absorbed by armor steel during dynamic loadings, such as a crash, impact, or blast, is crucial. To characterize the behaviour of material deformation under such loading, rigorous testing and a suitable material model are needed. Within the scope of this research, relevant tensile tests in the dynamic range are carried out to obtain the parameters necessary for three different material models, namely, the Johnson-Cook (J-C), Rusinek and Klepaczko (R-K), and a newly proposed modified Johnson-Cook (MJ-C) model. Tensile tests are simulated using these three material models, and the results are compared with the experimental results. The Charpy impact test at five different striking velocities, viz. 3, 4, 5, 6, and 8 ms−1 are numerically simulated using these material models. Upon comparing the obtained results with the experimental data, it becomes evident that the J-C model with modification (MJ-C) exhibits the best fit in prediction with regard to the specimen energy absorption and force versus displacement. A fractography investigation is also carried out to estimate the number of voids and void size with striking velocities. It shows that at higher strain rates, the number of voids increases. Additionally, the plastic deformation is restricted at high strain rates, leading to higher stress and reduced ductility.

Minimization of residual stress, surface roughness and tool wear in Electro Discharge Machining of inconel 625

Electro Discharge Machining (EDM) is a well-known non-traditional machining technique which is widely used to make die castings and turbine blades out of difficult-to-cut materials like Inconel 625. The machined part's surface quality and dimensional accuracy are affected by the EDM electrode's wear. Moreover, surface roughness and residual stress augmentation of EDM-machined components can reduce the workpiece's lifespan by decreasing the fatigue life of machined parts. To enhance the precision and durability of EDM machined components, residual stress, tool wear, and surface roughness should be evaluated and minimized. The majority of published research works for the assessment and optimization of EDM machining parameters are based on experimental works which are limited to testing, workpiece materials, and machining conditions. In order to improve the quality of machined surfaces and reduce tool wear and residual stress during Inconel 625 EDM processes, a virtual machining approach has been developed in the research work. To predict the cutting temperature during EDM operations, the modified Johnson Cook model of Inconel alloys is used. The finite element approach is then used to calculate the generated residual stress during the EDM process. The proposed virtual machining approach is also applied in order to predict the surface roughness of EDM machined parts. To minimize the residual stress, tool wear, and surface roughness during EDM operations of Inconel 625, the machining parameters of gap voltage, peak current, pulse-off time, and pulse-on time are optimized using the Taguchi optimization approach. Experiments and simulations are then conducted to verify the developed virtual machining system in the study. So, using the optimal machining parameters, the residual stress, surface roughness of machined items and wear of EDM electrode are minimized by 24.5 %, 25.4 %, and 25.4 % respectively. Thus, the quality and reliability of components made using EDM processes may be enhanced by the suggested virtual machining system.

A modified Johnson–Cook model for the plastic behavior of metals in ultrasonic vibration-assisted upsetting processes

In this work, we present a constitutive description of the plastic behavior of the metals and alloys under Ultrasonic Vibration (UV). When UV is imposed, it induces a softening effect on the plastic deformation of metals and alloys, referred to as the acoustoplastic phenomenon. The volumetric softening mechanism of the acoustoplasticity must consider stress superposition and acoustic softening. Taking the Johnson–Cook (JC) constitutive model as the reference for metal thermo-plasticity, the flow stress reduction due to UV is introduced by three types of softening terms: subtractive, multiplicative, and coupled. Those different configurations will be quantified via physical and phenomenological assumptions. For the study and validation of the proposed constitutive models, we focus on a well-known material, 6063 aluminum alloy. The ultrasonic vibration is modeled by an assisted upsetting process of an aluminum billet and compared with experiments. The impact of variations of the strain rate, ultrasonic amplitude, and frequency on the softening behavior of the models are analyzed and compared with available experimental results. We find out that the subtractive and coupled models agreed well with the experimental results showing the errors ranging from 2.4–4.8% and 4.4%–8%, respectively. However, the predictive ability of the multiplicative model exhibits large discrepancies at the low stage of strains following the acceptable predictions at high stains. By understanding the impact of the UV on the acoustoplastic deformation of the metals and alloys we can establish a reliable theoretical framework for prospective numerical studies of the UV-assisted manufacturing processes which is the goal of the current research presented here.

Modeling of strain hardening behaviors of 6061 aluminum alloy considering strain rate and temperature effects

This paper focuses on the plastic strain hardening behaviors of 6061 aluminum alloy (AA6061), considering its dependence on strain rate and temperature. Quasi-static tensile tests were conducted over a wide temperature range (20 °C-300 °C), and the digital image correlation technique was used to capture the deformation process of specimens. Additionally, the uniaxial compressive mechanical response of AA6061 was tested utilizing quasi-static compression and split Hopkinson pressure bar experiments over a wide range of strain rates (0.001 s−1–6000 s−1). Experimental results showed that the flow stress decreased and increased nonlinearly with temperature and strain rate, respectively. A modified Johnson–Cook (MJC) model was developed by incorporating a temperature-dependent strain softening term, along with corrections to the temperature and strain rate product terms, to reproduce the nonlinear dependence. Furthermore, the MJC model was proven to be able to accurately reproduce the deformation of the specimens tested in Taylor impact experiments (strain rates up to 105 s−1), suggesting its effectiveness for interpolating and extrapolating stress-strain relationships. This model provides applicable modeling for materials with nonlinear rate sensitivity and temperature sensitivity, and it is expected to be applied in engineering problems involving ultra-high strain rates.

Accuracy of Modified Johnson–Cook Modelling of the Blanking Process through Experimental and Numerical Analysis

Accuracy of Modified Johnson–Cook Modelling of the Blanking Process through Experimental and Numerical Analysis

A Modified Johnson–Cook Model for Modeling AA6061-T6 under Different Temperatures Considering Ductile Fracture

A Modified Johnson–Cook Model for Modeling AA6061-T6 under Different Temperatures Considering Ductile Fracture

A phenomenological constitutive model of Novel Rheo Gravity Die Cast Al-15Mg2Si-4.5Si-0.01Sr-0.015B composite

The present study discusses the high temperature deformation behaviour as well as phenomenological constitutive model development of the novel Rheo gravity die cast (RGDC) Al-15Mg2Si-4.5Si-0.01 Sr-0.015B composite. Within the scope of the study, uniaxial isothermal compression tests are performed on the RGDC Al-15Mg2Si-4.5Si-0.01 Sr-0.015B composite, covering a range of strain rates from 10−3 to 10 s−1 and deformation temperatures spanning from 250 °C to 450 °C. Analysis using X-ray Diffraction (XRD), Energy dispersive spectroscopy (EDS) and Electron Probe Micro Analyzer (EPMA) revealed the presence of distinct phases within the material, including primary Al, Mg2Si, and elemental Si. The study employed three different constitutive models i.e., the Johnson-Cook (JC), modified Johnson-Cook (mJC), and sine hyperbolic Arrhenius (shA) types, to predict the flow stress of the material as a function of strain, strain rate, and deformation temperature. The results indicated that the sine hyperbolic Arrhenius type model and the modified Johnson Cook model effectively accounted the coupling effect of strain, strain rate, and deformation temperature, which affect the flow stress. Statistical analysis, specifically Pearson coefficient correlation (R), average absolute relative error (AARE) and standard deviations, established a reasonable agreement between the predicted flow stress values and the experimental flow stress data. Furthermore, it is observed that the sine hyperbolic Arrhenius type model exhibited superior accuracy compared to the modified Johnson Cook model, particularly at higher strain levels.

Effect of Ultrasonic Vibration on Tensile Mechanical Properties of Mg-Zn-Y Alloy

Ultrasonic vibration assisted (UVA) plastic forming technology has proven to be a highly effective processing method, particularly for materials that are challenging to deform. In this research, UVA tensile tests were carried out on Mg98.5Zn0.5Y1 alloy at different vibration frequencies and amplitudes. The experimental results indicate that, compared with conventional tensile tests, the yield strength and tensile strength of Mg98.5Zn0.5Y1 alloy exhibit a decrease. Furthermore, the application of ultrasonic vibration demonstrates an ability to enhance the material’s elongation and plasticity. In order to further predict the stress-strain relationship in the metal tensile process, a hybrid constitutive model coupling the frequency and amplitude of ultrasonic vibration was developed based on the modified Johnson Cook model. The calculated results of the constitutive equation are in good agreement with the experimental results, indicating that the established constitutive equation can accurately predict the trend of alloy stress change at different amplitudes and frequencies. It establishes a theoretical foundation for scrutinizing the deformation mechanisms of the alloy under ultrasonic vibration. Furthermore, Abaqus finite element analysis software was employed to simulate and analyze the UVA tensile process, elucidating the impact of ultrasonic vibration on stress distribution, strain patterns, and material flow in the tensile behavior of Mg98.5Zn0.5Y1 alloys.

Dynamic Mechanical Behavior and Energy Release Effect of a Novel Nb17Zr33Ti17W33 High-Entropy Alloy under Impact Load

The present study successfully demonstrates the fabrication of a novel class of high-entropy alloy, namely Nb17Zr33Ti17W33, through suspension melting and casting technique. To investigate the dynamic mechanical behavior and energy release effects of the alloy under high-speed impact loads, various techniques were employed, including split Hopkinson pressure bar (SHPB), X-ray diffractometer (XRD), scanning electron microscope (SEM), and high-speed photography. These methods were utilized to acquire crucial data, such as crystal structure analysis, stress–strain curves, and microstructural examination of failed specimens. The modified Johnson–Cook (J-C) model was employed to elucidate the dynamic flow behavior of the alloy, while investigating the failure mechanism and energy release phenomenon during the process of dynamic compression. The experimental results demonstrate that the alloy material exhibits a dual-phase (BCC1 + BCC2) structure, exhibiting ductile fracture behavior under dynamic compression conditions. On the fracture surface, typical dimple structures along with evidence of shear slip and melting traces were observed, indicating an energy-releasing failure process. The newly developed alloy exhibited exceptional strength, high density, remarkable plasticity, and outstanding energy release properties, rendering it highly promising for applications under extreme loads.

Evaluation of constitutive equations for modeling and characterization of microstructure during hot deformation of sintered Al–Zn–Mg alloy

Commercial simulation software like QFORM and DEFORM do not possess adequate material data for alloys produced through powder metallurgy. Therefore, in the present study, hot compression tests of Al-5.6%Zn–2%Mg aluminum alloy were conducted at temperature ranges (300 0C-500 °C) and strain rates (0.1 s−1-0.0001 s−1). The impact of compression temperature and strain rate on the flow curve behaviour and microstructure evolution-associated mechanisms were investigated through experimentally acquired flow curves and EBSD analysis. Four constitutive models were constructed; namely the Arrhenius-type, modified Johnson Cook (MJC), modified Zerilli-Armstrong (MZA), and an artificial neural network (ANN). The results demonstrated that among the models considered, the ANN and Arrhenius-type models exhibited the lowest AARE values of 0.486 % and 3.36 %, respectively. Conversely, the MZA and MJC models displayed higher AARE values of 8.84 % and 3.93 %, respectively. Notably, the Arrhenius-type model emerged as the most suitable prediction model due to its capability to handle nonlinear relationships between factors. However, in scenarios where material properties are unknown or experimental data is limited, the MJC model can serve as a simpler alternative. The MZA model was deemed unsuitable for accurately estimating flow stress in hot compression. Remarkably, the best-trained ANN model exhibited the highest predictive performance with an AARE of 0.486 % and an R-value of 0.99. This study offers fundamental insights to improve the accuracy of simulating hot compression procedures. EBSD analysis demonstrated that higher upsetting temperatures and lower strain rates promoted recrystallization, resulting in a more uniform microstructure.

Study on thermal deformation constitutive model of NiCoFeAlCrMo high-entropy alloy with FCC / L12 coherent structure

Due to its multi-principal component characteristics, high-entropy alloys exhibit excellent comprehensive mechanical properties and become a new generation of engineering structure alternative materials. At present, a single constitutive model is used to describe the change of flow stress in the study of hot deformation behavior of high-entropy alloys, and there are some problems such as inaccurate prediction accuracy or inapplicability of the model in some hot processing intervals. In this paper, three different constitutive models are combined to fully consider the applicability of the model in different temperature ranges, and the change of flow stress behavior is accurately described, which is of great significance for subsequent deformation mechanism research, hot processing process optimization, numerical simulation and so on. Thermal compression experiments on cast Ni28.5Co18.6Fe18.2Al16.3Cr10.5Mo4 Ti2.3Nb0.6W0.9C0.2 high-entropy alloy were carried out using a Gleeble-3800 thermal simulation tester with deformation temperatures in the range from 900 ℃ to 1150 ℃ and strain rates from 0.001 s−1 to 1 s−1. The constitutive relationships between true stress and strain, temperature and strain rate were established, while the heat deformation process of this alloy under different deformation conditions by Arrhennius, Modified Johnson-Cook and Modified Fields-Backofen models were characterized. The results indicate that Arrenius model describe the rheological behavior of the alloy better in a wider temperature range and at a wider strain rate range. Comparatively, the model shows the highest prediction accuracy in the high-temperature region and slightly lower accuracy in the mesothermal and low-temperature regions. The modified J-C and F-B models have better prediction accuracy in the low-temperature and medium-temperature regions, respectively. Due to the different deformation conditions, dislocation configurations such as dislocation tangles, dislocation networks, and subcrystalline junctions can be observed in the plastic deformation region. The dislocation density of this alloy increases with increasing strain rate and decreasing deformation temperature after deformation.

Experimental and Numerical Study on the Perforation Behavior of an Aluminum 6061-T6 Cylindrical Shell.

The modified Johnson-Cook (MJC) material model is widely used in simulation under high-velocity impact. There was a need to estimate a strain rate parameter for the application to the impact analysis, where the method typically used is the Split Hopkinson bar. However, this method had a limit to the experiment of strain rate. This study proposed to estimate the strain rate parameter of the MJC model based on the impact energy and obtained a parameter. The proposed method of strain rate parameter calculation uses strain parameters to estimate from the drop weight impact and high-velocity impact experiments. Then, the ballistic experiment and analysis were carried out with the target of the plate and cylindrical shape. These analysis results were then compared with those obtained from the experiment. The penetration velocities of plates could be predicted with an error of a maximum of approximately 3.7%. The penetration shape of the cylindrical target has a similar result shape according to impact velocity and had an error of approximately 6%.

Compression properties and constitutive model of short glass fiber reinforced poly-ether-ether-ketone (PEEK)

To analyze the deformation behavior of short glass fiber-reinforced poly-ether-ether-ketone (SGFR-PEEK) under various conditions through numerical simulations, it is crucial to construct a constitutive model that can describe its stress–strain behavior over a wide range of strain rates and temperatures. In this study, quasi-static compression tests were conducted on SGFR-PEEK composites with varying mass fractions, and dynamic tests were performed using a Split Hopkinson Pressure Bar to acquire the material's compressive stress–strain response under quasi-static and dynamic conditions. The results indicate that, under compression, the yield stress of SGFR-PEEK composites increases with an augmentation in glass fiber content, rises with increasing strain rate, and decreases with elevated temperature. Based on experimental findings, a modified Johnson–Cook constitutive model was established to characterize the mechanical performance of SGFR-PEEK. In comparison to the traditional Johnson–Cook intrinsic structure model, the modified model takes into account the glass fiber mass fraction as comprehensively as possible and better predicts the material's flow behavior at high strain rates. Finally, this modified constitutive model was implemented in the ABAQUS software using the user-defined subroutine VUMAT to simulate the compression behavior of SGFR-PEEK composites under different loading conditions, and the model was validated. This research provides valuable insights for the practical application of SGFR-PEEK composites in engineering.