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Lester, Brian T.

Publications and source records attributed to Lester, Brian T..

At least 37 records · Page 2
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

A publicly available PyTorch-$\mathrm{ABAQUS}$ $\mathrm{UMAT}$ deep-learning framework for level-set plasticity

Here this paper introduces a publicly available PyTorch-ABAQUS deep-learning framework of a family of plasticity models where the yield surface is implicitly represented by a scalar-valued function. In particular, our focus is to introduce a practical framework that can be deployed for engineering analysis that employs a user-defined material subroutine (UMAT/VUMAT) for ABAQUS, which is written in FORTRAN. To accomplish this task while leveraging the back-propagation learning algorithm to speed up the neural-network training, we introduce an interface code where the weights and biases of the trained neural networks obtained via the PyTorch library can be automatically converted into a generic FORTRAN code that can be a part of the UMAT/VUMAT algorithm. To enable third-party validation, we purposely make all the data sets, source code used to train the neural-network-based constitutive models, and the trained models available in a public repository. Furthermore, the practicality of the workflow is then further tested on a dataset for anisotropic yield function to showcase the extensibility of the proposed framework. A number of representative numerical experiments are used to examine the accuracy, robustness and reproducibility of the results generated by the neural network models.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Validation of material models for puncture of 7075-T651 aluminum plate

Plate puncture simulations are challenging computational tasks that require advanced material models including high strain rate and thermal-mechanical effects on both deformation and failure, plus finite element techniques capable of representing large deformations and material failure. The focus of this work is on the material issues, which require large sets of experiments, flexible material models and challenging calibration procedures. In this study, we consider the puncture of 12.7 mm thick, 7075-T651 aluminum alloy plates by a cylindrical punch with a hemispherical nose and diameter of 12.7 mm. The plasticity and ductile failure models were isotropic with calibration data obtained from uniaxial tension tests at different temperatures and strain rates plus quasi-static notched tension tests and shear-dominated tests described here. Sixteen puncture experiments were conducted to identify the threshold penetration energy, mode of puncture and punch acceleration during impact, The punch was mounted on a 139 kg mass and dropped on the plates with different impact speeds. Since the mass was the same in all tests, the quantity of interest was the impact speed. The axis and velocity of the punch were perpendicular to the plate surface. The mean threshold punch speed was 3.05 m/s, and the mode of failure was plugging by thermal-mechanical shear banding accompanied by scabbing fragments. Application of the material models in simulations of the tests yielded accurate estimates of the threshold puncture speed and of the mode of failure. Time histories of the punch acceleration compared well between simulation and test. Remarkably, the success of the simulations occurred in spite of even the smallest element used being larger than the width of the shear bands.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Comprehensive Material Characterization and Simultaneous Model Calibration for Improved Computational Simulation Credibility

Computational simulation is increasingly relied upon for high-consequence engineering decisions, and a foundational element to solid mechanics simulations is a credible material model. Our ultimate vision is to interlace material characterization and model calibration in a real-time feedback loop, where the current model calibration results will drive the experiment to load regimes that add the most useful information to reduce parameter uncertainty. The current work investigated one key step to this Interlaced Characterization and Calibration (ICC) paradigm, using a finite load-path tree to incorporate history/path dependency of nonlinear material models into a network of surrogate models that replace computationally-expensive finite-element analyses. Our reference simulation was an elastoplastic material point subject to biaxial deformation with a Hill anisotropic yield criterion. Training data was generated using either a space-filling or adaptive sampling method, and surrogates were built using either Gaussian process or polynomial chaos expansion methods. Surrogate error was evaluated to be on the order of 10 ⁻5 and 10 ⁻3 percent for the space-filling and adaptive sampling training data, respectively. Direct Bayesian inference was performed with the surrogate network and with the reference material point simulator, and results agreed to within 3 significant figures for the mean parameter values, with a reduction in computational cost over 5 orders of magnitude. These results bought down risk regarding the surrogate network and facilitated a successful FY22-24 full LDRD proposal to research and develop the complete ICC paradigm.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Impact of Integration Scheme on Performance of Anisotropic Plasticity Models

Given the prevalent role of metals in a variety of industries, schemes to integrate corresponding constitutive models in finite element applications have long been studied. A number of formulations have been developed to accomplish this task; each with their own advantages and costs. Often the focus has been on ensuring the accuracy and numerical stability of these algorithms to enable robust integration. While important, emphasis on these performance metrics may often come at the cost of computational expense potentially neglecting the needs of individual problems. In the current work, the performance of two of the most common integration methods for anisotropic plasticity -- the convex cutting plane (CCP) and closest point projection (CPP) -- across a variety of metrics is assessed; including accuracy and cost. A variety of problems are considered ranging from single elements to large representative simulations including both implicit quasistatic and explicit transient dynamic type responses. The relative performance of each scheme in the different instances is presented with an eye towards guidance on when the different algorithms may be beneficial.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Thermal-Mechanical Elastic-Plastic and Ductile Failure Model Calibrations for 6061-T651 Aluminum Alloy from Plate

Numerical simulations of metallic structures undergoing rapid loading into the plastic range require material models that accurately represent the response. In general, the material response can be seen as having four interrelated parts: the baseline response under slow loading, the effect of strain rate, the conversion of plastic work into heat and the effect of temperature. In essence, the material behaves in a thermal-mechanical manner if the loading is fast enough so when heat is generated by plastic deformation it raises the temperature and therefore influences the mechanical response. In these cases, appropriate models that can capture the aspects listed above are necessary. The matters of interest here are the elastic-plastic response and ductile failure behavior of 6061-T651 aluminum alloy under the conditions described above. The work was accomplished by first designing and conducting a material test program to provide data for the calibration of a modular $J_2$ plasticity model with isotropic hardening as well as a ductile failure model. Both included modules that accounted for temperature and strain rate dependence. The models were coupled with an adiabatic heating module to calculate the temperature rise due to the conversion of plastic work to heat. The test program included uniaxial tension tests conducted at room temperature, 150 and 300 C and at strain rates between 10 –4 and 10 3 1/s as well as four geometries of notched tension specimens and two tests on specimens with shear-dominated deformations. The test data collected allowed the calibration of both the plasticity and the ductile failure models. Most test specimens were extracted from a single piece of plate to maintain consistency. Notched tension tests came from a possibly different plate, but from the same lot. When using the model in structural finite element calculations, element formulations and sizes different from those used to model the test specimens in the calibration are likely to be used. A brief investigation demonstrated that the failure model can be particularly sensitive to the element selection and provided an initial guide to compensate in a specific example.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Thermal-Mechanical Elastic-Plastic and Ductile Failure Model Calibrations for 304L Stainless Steel Alloy

Numerical simulations of metallic structures undergoing rapid loading into the plastic range require material models that accurately represent the response. In general, the material response can be seen as having four interrelated parts: the baseline response under slow loading, the effect of strain rate, the conversion of plastic work into heat and the effect of temperature. In essence, the material behaves in a thermal-mechanical manner if the loading is fast enough so when heat is generated by plastic deformation it raises the temperature and therefore influences the mechanical response. In these cases, appropriate models that can capture the aspects listed above are necessary. The material of interest here is 304L stainless steel, and the objective of this work is to calibrate thermal-mechanical models: one for the constitutive behavior and another for failure. The work was accomplished by first designing and conducting a material test program to provide data for the calibration of the models. The test program included uniaxial tension tests conducted at room temperature, 150 and 300 C and at strain rates between 10 –4 and 10 3 1/s. It also included notched tension and shear-dominated compression hat tests specifically designed to calibrate the failure model. All test specimens were extracted from a single piece of plate to maintain consistency. The constitutive model adopted was a modular $J_2$ plasticity model with isotropic hardening that included rate and temperature dependence. A criterion for failure initiation based on a critical value of equivalent plastic strain fitted the failure data appropriately and was adopted. Possible ranges of the values of the parameters of the models were determined partially on historical data from calibrations of the same alloy from other lots and are given here. The calibration of the parameters of the models were based on finite element simulations of the various material tests using relatively ne meshes and hexahedral elements. When using the model in structural finite element calculations, however, element formulations and sizes different from those in the calibration are likely to be used. A brief investigation demonstrated that the failure initiation predictions can be particularly sensitive to the element selection and provided an initial guide to compensate for the effect of element size in a specific example.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Topological damping materials and methods thereof

The present invention features a metamaterial including a plurality of unit cells, in which each unit cell includes two interacting members to dissipate energy. Also provided herein are assemblies including such metamaterials and methods of manufacture.

Boyce, Brad↗
DOE OSTI2020

Library of Advanced Materials for Engineering (LAMÉ) 4.58

Accurate and efficient constitutive modeling remains a cornerstone issue for solid mechanics analysis. Over the years, the LAMÉ advanced material model library has grown to address this challenge by implementing models capable of describing material systems spanning soft polymers to stiff ceramics including both isotropic and anisotropic responses. Inelastic behaviors including (visco)plasticity, damage, and fracture have all incorporated for use in various analyses. This multitude of options and flexibility, however, comes at the cost of many capabilities, features, and responses and the ensuing complexity in the resulting implementation. Therefore, to enhance confidence and enable the utilization of the LAMÉ library in application, this effort seeks to document and verify the various models in the LAMÉ library. Specifically, the broader strategy, organization, and interface of the library itself is first presented. The physical theory, numerical implementation, and user guide for a large set of models is then discussed. Importantly, a number of verification tests are performed with each model to not only have confidence in the model itself but also highlight some important response characteristics and features that may be of interest to end-users. Finally, in looking ahead to the future, approaches to add material models to this library and further expand the capabilities are presented.

36 MATERIALS SCIENCE↗