Plastic Strain Distribution Research Articles

Optimization of Ti-6Al-4V ring rolling process by FE simulation using RSM

Ring rolling is a process to manufacture seamless rings. The process is characterised by high non-linearity, asymmetry, unsteady state and non-uniformities in plastic strain and temperature distribution in the ring cross-section. Inhomogeneities in distribution of plastic strain and temperature have significant effects on deformation behavior, microstructure and mechanical properties. Fishtail defect, one of the form defects, is also a major concern. In this study, a reliable coupled 3D thermo-mechanical finite element model of the ring rolling process was developed using dynamic explicit code in ABAQUS/Explicit environment. Nine simulations with different combinations of feed rate and rotational speed were ascertained using Central Composite Design (CCD). CCD model is an integral part of Response Surface Methodology (RSM). Strain and temperature heterogeneities and fishtail defect were predicted using the simulated models. Coefficient of Variation (CoV) was introduced as a heterogeneity index for strain and temperature analysis. The fishtail coefficient was used to quantify fishtail defect. ANOVA was carried to find out the significant factors and interactions affecting the ring rolling process. Feed rate was found to be the only significant factor in the range of parameters studied. Multi-response optimization was performed to find out the feed rate at which the process is most optimized with an aim to minimize both strain and temperature heterogeneity and fishtail defect. Feed rate of 1.61 mm/s was found to be the most optimized process parameter.

Modeling Sequences of Earthquakes and Aseismic Slip (SEAS) in Elasto‐Plastic Fault Zones With a Hybrid Finite Element Spectral Boundary Integral Scheme

AbstractWe present a coupled finite element spectral boundary integral framework for modeling sequences of earthquakes and aseismic slip on a 2‐D planar rate‐and‐state fault with off‐fault visco‐plastic response in the plane strain approximation. The model resolves both slow aseismic deformation and inertia effects during rapid slip. As an application, we perform two sets of simulations with different choices of cohesion to explore the co‐evolution of fault slip, bulk plasticity and local stress fields. The first set implements a relatively large value of the cohesion parameter, which results in limiting inelastic strain accumulation to dynamic rupture phases. The second set implements a smaller cohesion, allowing for plastic strain to accumulate in both seismic and aseismic phases. For the first model, our results indicate that the extent and distribution of plastic strain depend on the angle of maximum compressive principal stress. At larger angles, inelastic strain accumulates on the extensional side of a dynamically propagating rupture. At smaller angles, the extent of plasticity is limited to the compressional side of the domain. At smaller cohesion values, off‐fault plasticity may occur during aseismic slip, which alters the nucleation characteristics and earthquake sequence pattern. Furthermore, our results at lower cohesion values indicate that plastic strain accumulation may occur in both the extensional and compressional sides of the off‐fault bulk even at higher angles of maximum compression. This produces damage patterns that deviate from the traditional off‐fault fan‐like distribution observed in dynamic rupture simulations and emphasizes the significance of long‐term deformation in interpreting observations.

Computational and experimental investigation of the strain rate sensitivity of small punch testing of the high-entropy alloy CoCrFeMnNi

The suitability of determining the strain rate sensitivity (SRS) of the CoCrFeMnNi high-entropy alloy (HEA) by small punch (SP) testing has been assessed at displacement rates ranging from 0.2 to 2 mm∙min−1. The stress was found to increase as the displacement rate was raised from 0.2 to 2 mm∙min−1, whereas the plastic strain distributions were similar in all cases. However, for a higher displacement rate of 10 mm∙min−1, the sample was found to exhibit a drop in strength and ductility attributed to casting defects. The strain-rate sensitivity exponent (m) was found to be 0.1387 whilst the Finite Element Analysis (FEA) simulations predicted a slightly smaller value of 0.1313. This latter value is closer to m = 0.091 obtained from nanoindentation strain rate jump tests since the results are insensitive to the presence of small casting defects. The relationship between the experimental and the empirically derived predicted properties from the SP tests revealed a high level of agreement for maximum stress properties. The properties predicted at 2 mm∙min−1 (R2 = 0.96) offered a stronger fit than at 0.5 mm∙min−1 (R2 = 0.92).

Micromechanical modeling of damage evolution and fracture behavior in particle reinforced metal matrix composites based on the conventional theory of mechanism-based strain gradient plasticity

The particle/matrix interface of metal matrix composites (MMCs) can give rise to extra strength and then affect the local deformation behavior. This strengthening effect originates from the plastic strain gradients due to the incompatibility of plastic deformation between the particle and matrix. However, only limited researches utilized the strain gradient plasticity to study the damage evolution and fracture behavior, in which only one or two of the damage mechanisms (i.e., matrix damage, interface debonding, and particle fracture) was considered. In this work, all of these damage mechanisms were coupled into the finite element model under conventional theory of mechanism-based strain-gradient (CMSG) plasticity. Besides, a new numerical algorithm of geometrically necessary dislocations (GNDs) was proposed for a multi-scale model, and then this model was used to analyze the damage evolution and failure behavior of SiCp/AZ91 composite. The results show that the strengthening effects of plastic strain gradients can describe interface debonding, break the monotonicity of the effective plastic strain with the effective stress at the local area close to the particle/matrix interface, and give a more reasonable distribution of stress and plastic strain compared to the classical J2 flow theory. If the probability distribution of the interfacial strength is considered, the CMSG model has the potential capacity to capture the crack initiation in the matrix. When using the continuum damage mechanics approach to describe the fracture process based on the multi-scale model, the weakening exponent value should be considered.

Effect of in-lath slip strength on the strain partitioning in a dual-phase steel investigated by high-resolution digital image correlation and crystal plasticity simulations

In this study, the effect of different modeling hypotheses for the plastic deformation of lath martensite was investigated through an integrated experimental–numerical approach. The local plastic strain distribution of a dual-phase steel with a coarse microstructure was quantified by high-resolution digital image correlation analysis. The same area was reproduced in a crystal plasticity finite element model using the electron backscatter diffraction measurement of the specimen surface prior deformation. Different modeling hypotheses in terms of in-lath and out-of-lath slip strength as well as boundary and bulk elements were explored. It was found that early plastic deformation in lath martensite grains predominantly took place at various interfaces in the form of slip bands parallel to the in-lath slip planes in blocks exhibiting high in-lath Schmid factor. A comparison between experiment and simulations suggested that assuming a lower strength and hardening rate for in-lath slip systems of boundary elements better reproduced the plastic strain fields in martensite grains. However, the different models showed limited effect on the strain distribution within ferrite grains and on the local stress–strain path at void nucleation sites. This suggested that the main factor affecting early strain concentration and subsequent damage initiation in ferrite grains was the phase morphology and strength contrast.

Study on fracture behavior of pipeline girth weld based on CTOD-Am method and Gurson ductile damage model

The mechanical properties of the materials in different regions of the pipeline girth weld are sometimes quite different, which will produce a more significant material constraint effect and complicate the fracture behavior of the girth weld. Therefore, this work adopts the finite element method combined with the material damage model to study the ductile tearing process of the weld. The results of the single edge notched bending (SENB) specimens with the weld center crack show that for the welds with different mismatch conditions, with the increase of the weld mismatch coefficient, the crack tip constraint decreases gradually, and the fracture toughness increases gradually. The smaller weld width will make this effect more significant. When the ratio of the weld width to the specimen width is larger than or equal to 0.43, the BM will basically no longer affect the crack tip constraint and the fracture toughness of the weld. The results of the SENB specimens with the interface crack show that for the overmatched weld, with the increase of the weld mismatch coefficient, the crack first grows along the interface and then deflects into the heat affected zone (base metal). When the weld mismatch coefficients are 1.44 and 1.86, the corresponding deflection angles are 14.84° and 24.61°. For undermatched weld, with the decrease of the weld mismatch coefficient, the crack growth will deflect into the weld metal. When the weld mismatch coefficients are 0.69 and 0.6, the corresponding crack growth deflection angles are 14.04° and 25.36°. The larger the degree of the weld mismatch, the more significant the deflection of the distribution of the equivalent plastic strain and the stress triaxiality ahead of the crack tip. The effect of the specimen thickness on the deflection angle of the interface crack growth is small. The verification shows that the numerical analysis results of this study are valid.

Strain mapping in fine scale multivariant α structures in titanium alloys

High-strength metastable β alloys typically contain sub-micron scale distributions of the α phase in a matrix of β grains. An understanding of plasticity in such microstructures is limited. We describe here techniques to deposit, at room temperature, patterns of Au nanoparticles for digital image correlation, which are consistent with the scale of the structure. The alloy Ti 5553 has been aged to different volume fractions of the α phase and strained in compression to demonstrate the efficacy of this DIC technique. The data is complemented with electron back scattered diffraction to correlate the microstruture with the plastic strain distribution, and preliminary analysis of strain partitioning between the two phases.

Fatigue crack propagation across grain boundary of Al-Cu-Mg bicrystal based on crystal plasticity XFEM and cohesive zone model

In this paper, a methodology integrating crystal plasticity (CP), the eXtended finite element method (XFEM) and the cohesive zone model (CZM) is developed for an Al-Cu-Mg alloy to predict fatigue crack propagation (FCP) across grain boundary (GB) of Al-Cu-Mg alloy during stage ІІ. One GB model is incorporated into FCP constitutive law to describe grain interaction at GB. A bicrystal containing GB is built up to simulate FCP behavior through L participated GBs. Modelling features including GB characteristic, cumulative plastic strain (CPS) distribution and crystal slipping evidence can be identified. The numerical results are compared with published experimental data to check the accuracy of model. This work demonstrates that the combination of CP containing GB constitutive laws, XFEM and CZM is a promising methodology in predicting twist angle-controlled crack deflection through GBs.

Surgically-induced deformation in biodegradable orthopaedic implant devices

The biocompatibility and mechanical performance of biodegradable metals (e.g. magnesium, iron, and zinc-based alloys) in orthopaedic-targeted applications are contingent on limiting the rate of corrosion in vivo throughout the bone healing. Concurrently, the surgical procedure for the implantation of internal bone fixation devices may impart plastic deformation to the device, potentially altering the corrosion rate of the device. However, the potential effect of the surgical implantation procedure on the mechanochemical performance of metallic degradable orthopaedic devices in vivo remains largely unresolved. The objective of the present study is to develop a robust technique that permits the quantification of the strain introduced due to surgical implantation of degradable orthopaedic devices. Specifically, a novel combined experimental-modelling approach based on 3D laser scanning in situ and the finite element method is utilised to quantify the plastic strain introduced to a bone fixation plate following surgical implantation in a cadaveric porcine model where the plate is based on a ternary magnesium-zinc-calcium alloy (ZX10). The magnitude of plastic strains determined by the above approach for the Mg craniofacial miniplate confirms that the surgical procedure itself has the potential to enhance the corrosion rate of the Mg alloy in an accelerated and potentially localised manner. Statement of SignificanceBiodegradable metallic orthopaedic implant devices have emerged as a potential alternative to permanent implants, although successful adoption is contingent on achieving an acceptable degradation profile. Plastic strain that is introduced to the device during surgical implantation may influence the resulting degradation behaviour of the implant. In the present work, 3D laser scanning is combined with computer simulation to estimate the level and distribution of surgically-induced plastic strain in a magnesium alloy (ZX10). Subsequently, clinically-relevant pre-strain is shown to influence the rate of corrosion of ZX10 in vitro, indicating the value of such an approach in the design of biodegradable metallic devices under multiaxial loading.

Surface Nanocrystallization and Numerical Modeling of 316L Stainless Steel during Ultrasonic Shot Peening Process

Surface nanocrystallization of metals and alloys via high-frequency ultrasonic shot peening (USP) can significantly increase the mechanical properties of the materials. However, the relationship between the external process parameters and the internal microstructure of the materials is still unclear and an accurate numerical model to simulate the USP process is urgently required for better control of the grain refinement process. In this study, we successfully realized surface nanocrystallization of 316L stainless steel using USP with an ultrasonic frequency and amplitude of 20 kHz and 50 μm, respectively. The microstructure evaluation of 316L stainless steel during USP was revealed. We established a finite element numerical model to simulate the high-frequency USP process and calculated the plastic strain and stress distribution of 316L stainless steel during the grain refinement process. We investigated the effects of the ultrasonic frequency, working distance, and ultrasonic amplitude on the plastic strain and stress distribution on the materials using the finite element simulation method. The dynamic behavior of the shot during the USP process was studied using a high-speed camera, and the FE simulation results agreed well with the experimental results. We also investigated the impact of multiple shots during the USP process by the high-speed camera observation and FE simulation. Research results indicate that high-frequency USP is an effective method to obtain large-scale bulk nanocrystalline materials and the finite element simulation can help materials scientists and engineers to better understand the relationship between the process parameters and microstructure evaluation of 316L stainless steel.

Investigation of mechanical properties of laser welded dual-phase steels at macro and micro levels

The current automotive industry uses new technology in materials processing and lightweight materials to minimize vehicle weight and fuel consumption. As a result, Tailor-Welded Blanks (TWB) are used in regions where additional strength or stiffness is necessary in body-in-white, thus decreasing weight. In this paper, TWB were produced by joining DP600 with 1.8 mm and DP800 with 0.8 mm and 1.5 mm using CO2 laser welding. The effects of laser power and welding speed on the mechanical properties of TWB were investigated. The flow behaviors of the TWB were obtained from tensile tests. The microstructures of the weld zones of the base materials and TWB were revealed, and the numerical analyzes of the microstructures were performed by micromechanical modeling with a 2D representative volume element (RVE). Effective stress and plastic strain distributions in the microstructures and macroscopic flow curves of the base materials and the weld zones were obtained. The uniaxial tensile tests of the samples were modeled, and the flow behaviors of the TWB were obtained with micromechanical modeling. The results showed a significant change in stress distribution and strain localization depending on the grain size of constituents and the thickness ratios of the TWB at micro and macro scales, respectively. The numerical flow curves obtained using the RVE method were in good agreement with those of the experimental.

A Numerical Study of Friction Stir Welding for AA5754 Sheets to Evaluate Temperature Profile and Plastic Strain

A full-dimensions 3-D numerical model based on the Lagrangian approach has been employed to predict the peak temperature and the plastic strain distribution in the FSW of (AA5754) joints using ABAQUS software. The material’s model utilizes the classical plasticity model in addition to defining the thermophysical properties of the alloy using JMatPro software to increase the accuracy of the numerical results. The basic variables of FSW were three rotational speeds (930, 1460, and 1860 rpm) and three traverse speeds (35, 65, and 95 mm/min). The influence of the rotational and traverse speed on temperature profile and plastic strain has been studied. The simulation results showed that increasing the rotational speed led to increasing the peak temperature, which concentrated under the tool’s bottom surface while increasing the traverse speed decreased the peak temperature recorded. The highest peak temperature was (497 oC) at a rotational speed of (1860 rpm) and a traverse speed of (35 mm/min). It was also found that the rotational speed increased the plastic strain starting from the tool’s neck and continuing along the pins’ position and gradually decreasing towards the bottom. In addition, a V-shape pattern has appeared in the temperature distribution across the workpiece’s cross-section, representing the heat loss during the FSW by the backplate due to heat conductance.

Synergetic-Deformation-Induced Strengthening in Gradient Nano-Grained Metals: A 3D Discrete Dislocation Dynamics Study

Gradient nano-grained (GNG) metals have shown high synergetic strength and good ductility due to their unique gradient microstructure. In this study, the mechanical behavior of gradient nano-grained metals was investigated by three-dimensional discrete dislocation dynamics. The simulation results show a trend that the successive yielding and gradual “transmission” of dislocations along the gradient direction result in a gradient distribution of stress and plastic strain. The distribution of geometrically necessary dislocations is more inhomogeneous in the gradient nano-grained (GNG) sample compared with those homogenous counterparts. The non-uniform deformation response of component layers induces the synergetic-deformation-induced (SDI) strengthening in the GNG sample. The back stress originates from geometrically necessary dislocations that pile up near the interface of gradient layers and leads to a significant hardening while there is a slight softening in different gradient layers in the GNG sample. This study provides a deeper insight into the SDI strengthening in gradient structure from the submicron scale.

Plasticity-induced damage and material loss in oscillatory contacts

Knowledge of plasticity-induced damage leading to the loss of material in oscillatory contacts is of paramount importance to various electromechanical systems comprising contact-mode elements exposed to high-frequency vibrations. However, experimental investigation of the wear behavior of devices experiencing microscopic oscillatory contact (fretting) is complex, time consuming, and expensive. More importantly, the progression of critical damage processes, such as the decrease of the material’s strength with the accumulation of plastic deformation in the vicinity of the contact interface and the removal of material in the form of microscopic wear debris, cannot be tracked in real time, necessitating cumbersome and costly post-testing microanalysis. Alternatively, computational wear modeling is more effective than experiments and can provide valuable insight into the effect of important parameters, such as load, coefficient of friction, oscillation amplitude, and material behavior, on the loss of material during oscillatory sliding contact. Accordingly, the principal objective of this study was to introduce a computational approach, which can be used to analyze the loss of material due to plasticity-induced damage in oscillatory mechanical components. To achieve this aim, a plane-strain finite element model of a rigid cylinder in reciprocating sliding contact with an elastic-plastic half-space exhibiting isotropic strain hardening was used to study how the evolution of damage due to the progression of plasticity leads to the loss of material. A quasi-static, isothermal damage model based on a ductile failure criterion was implemented in the finite element analysis to simulate the removal of the fully damaged elements. Numerical results illuminate the effects of the load and coefficient of friction on the development of plasticity, cumulative damage, and loss of material with accruing oscillation cycles. The deviation of the wear behavior from classical wear theory in the high-load simulations is explained by the plastic shear strain distribution and less slip at the contact interface encountered at high loads. The novelty of this study is the development of a computational methodology, which sheds light into the evolution of plasticity, damage, and loss of material in reciprocating sliding contacts and provides an effective computational capability for assessing the effects of load, friction, and material behavior on the mechanical performance of components operating in oscillatory contact mode.

Thermal properties and thermal cycling stability of graphite/copper composite fabricated by microwave sintering

Herein, graphite/copper (Gr/Cu) composites were fabricated by mechanical mixing and microwave sintering to investigate the effect of graphite volume fraction on the thermal conductivity (TC) and coefficient of thermal expansion (CTE) of the Gr/Cu composite. The TC and CTE of the composites were measured in the in-plane and through-plane directions. The obtained results revealed that the graphite volume fraction significantly affects the TC and CTE of Gr/Cu composites. A lower volume fraction led to higher thermal properties. The effect of thermal cycling on the thermal properties of metal matrix composites (MMCs) has remained largely unexplored. In this work, the effect of thermal cycling on the thermal properties of MMCs was investigated in a temperature range of −196°C/+200 °C. The thermal cycling resulted in a staged decrease of TC and a gradual increase in CTE. This could be mainly attributed to the CTE mismatch between the Cu matrix and the Gr phase. Observations by scanning electron microscopy (SEM) showed that thermal cycling created the micro-cracks and micro-voids in the composites, as well as the sliding and detachment of the Gr/Cu interface. The distribution of thermal stress and plastic strain during thermal cycling was simulated by the finite element method. The changes in TC and CTE are discussed regarding thermally induced stress.

Microstructure and mechanical behavior of Ti/Cu/Ti laminated composites produced by corrugated and flat rolling

Ti/Cu/Ti laminated composites were fabricated by corrugated rolling (CR) and flat rolling (FR) method. Microstructure and mechanical properties of CR and FR laminated composites were investigated by scanning electron microscopy, numerical simulation methods, peel and tensile examinations. The effect of CR and FR was comparatively analyzed. The results showed that the CR and FR laminated composites exhibited different effective plastic strain distributions of the Ti layer and Cu layer at the interface. The recrystallization texture, prismatic texture and pyramidal texture were developed in the Ti layer by CR, while the R-Goss texture and shear texture were developed in the Cu layer by CR. The typical deformation texture components were developed in the Ti layer and Cu layer of FR laminated composites. The CR laminated composites had higher bond strength, tensile strength and ductility.

The Role of Interfacial Adhesion on the Mechanical Behavior of Thin Metal/Polymer Laminate with Surface Roughness.

Metal/polymer laminate has versatile applications in industry due to the essential roles of its constituents in controlling its mechanical behavior. Therefore, efforts to enhance a laminate’s performance should target its mechanical behavior. One of the most influencing features of the mechanical behavior of this type of thin laminate is the interface layer properties. This study concentrates on the mechanical response of thin aluminum (Al) foil deposited on a polymer substrate by calibrating its interfacial layer properties based on available uniaxial tensile tests performed on thin Al/polymer laminate. Then, taking into account the calibrated parameters for the interface layer, which leads to mimicking the real conditions of the laminate, one type of imperfection is introduced as a wavy roughness on the surface of each layer with different amplitudes to investigate its influence on the overall mechanical behavior of the laminate and its failure mode. The results highlighted that the existence of the roughness on the surface of the polymer layer reduces the maximum engineering stress of the laminate more severely compared to other conditions. As the roughness amplitude increases, the maximum stress reduces a lot. The distribution of equivalent plastic strains represents the appearance of the shear bands in the Al layer and an almost uniform distribution for the polymer layer. In the case of existing roughness on each layer, a higher amount of plastic strain accumulation occurs in the middle of the polymer layer and top corners of the thin Al layer. Due to the significant effect of interfacial layer properties to improve the maximum strength of the laminate and its final elongation, a parametric study is performed, taking into account different interfacial properties. The results indicate that laminate behavior with weaker separation properties in the interface layer is mostly unaffected by adopting higher tractions, and no change happens in the case of high separation considering weak tractions.

Compressive deformation behavior and microstructure evolution of AA2099 Al–Li alloy containing Al3Li precipitates based on experimental characterization and crystal plasticity finite element simulation

Deformation behavior of AA2099 Al–Li alloy containing Al3Li (δ′) precipitates at room temperature has been systematically investigated via uniaxial compression experiments, electron backscatter diffraction (EBSD) and transmission electron microscopy (TEM) measurements as well as crystal plasticity finite element (CPFE) simulation. By applying an appropriate heat treatment, these nano-sized δ′ precipitates with the diameter of 10–20 nm are obtained in AA2099 Al–Li alloy and the corresponding area fraction is about 1.12%. Microstructure characterizations confirm that these pre-existing δ′ precipitates survive during plastic deformation, meanwhile they would contribute to the formation of tangled and dense dislocations in Al matrix. An ingenious strategy is then proposed and coupled into the CPFE modeling to take account of the effect of δ′ phase on deformation behavior, namely δ′ precipitates contribute to the activity of co-planner slip and they are adverse to the activity of co-directional slip. These predicted mechanical behavior and texture evolution agree well with those experimentally measured ones, which verifies the validity of the conducted CPFE simulation. Moreover, CPFE modeling successfully predicts the occurrence of large and inhomogeneous Von Mises stress and dislocation density distribution in the case with δ′ phase. Besides, the statistical analysis on the coefficient variant about equivalent plastic strain strongly illustrates that these pre-existing δ′ precipitates contribute to the inhomogeneous distribution of plastic strain during plastic deformation.

Preparation, microstructure, and mechanical behaviour of Ni3Al-based superalloy reinforced with carbide particles

The preparation, microstructure, and mechanical behaviour of Ni3Al-based superalloy have been studied. The superalloy reinforced with carbide particles forming in-situ in the melt was prepared by vacuum induction melting (VIM) followed by centrifugal casting. The as-cast alloy was subjected to heat treatment consisting of solid solution annealing, quenching, and ageing. The microstructure of the heat-treated superalloy consists of blocky MC carbides (6.9 vol%), which are uniformly distributed within the columnar grains containing cuboidal γ′(Ni3Al) precipitates (57.3 vol%) embedded in the γ (Ni-based solid solution) matrix and along γ′ grain boundaries. The equivalent plastic strain distribution in the plastic zone underneath Vickers macroindentation and within the compression specimens deformed to engineering strains ranging from 0.05 to 0.27 is calculated using finite element analysis (FEA). The correlation curve between experimentally measured Vickers microhardness values and calculated equivalent plastic strains has been proposed to quantify the level of local strain hardening state of the studied Ni3Al-based superalloy. The room temperature compressive strain hardening behaviour is evaluated and measured strain hardening exponent and strain hardening rate are discussed.

A quantitative interphase model for polymer nanocomposites: Verification, validation, and consequences regarding size effects

The enhanced mechanical behavior of polymer nanocomposites with spherical filler particles is attributed to the formation of matrix-filler interphases. The nano-scale leads to particularly high interphase volume fractions while rendering experimental investigations extremely difficult. Previously, we introduced a molecular dynamics-based interphase model capturing the crucial spatial profiles of elastic and inelastic properties inside the interphase. This contribution demonstrates that our model captures polymer nanocomposites’ essential characteristics reported from experiments. To this end, we thoroughly verify and validate the model before discussing the resulting local plastic strain distribution. Furthermore, we obtain a reinforcement in terms of the overall stiffness for smaller particles and higher filler contents, while the influence of particle spacing seems negligible, matching experimental observations in the literature. This paper proposes a methodology to unravel the underlying complex mechanical behavior of polymer nanocomposites and to translate the findings into engineering quantities accessible to a broader audience and technical applications.