HIGH ELECTROTECHNICAL SCHOOL VELS

VISOKA ELEKTROTEHNIKA KOLA

VARADIN
CROATIA

OpenFOAM in Non-linear Stress Analysis:

Modelling of Adhesive Joints
Dr Vlado Tropa
Current Position:
Previous Position Held:

Lecturer of Solid Mechanics, VELS

Research Associate 1999-2004

Imperial College
London
Co-Authors: I. Georgiou, A. Ivankovic, A.J. Kinloch, J.G. Williams
OpenFOAM Workshop, Zagreb, Croatia, January 26-28, 2006

VELS, Varadin, Croatia

Outlines

Introduction Adhesives in Automotive Applications

Experimental Procedures
IWP method (Impact Wedge Peel)

Numerical Simulations (Finite Volume Method)

Conclusions
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Introduction Adhesives in Automotive Applications

Adhesive bonding - alternative method for automotive manufacturers?

Efficient for joining thin-sheet materials

Light-weight structures
Applicable for joining dissimilar materials
Cost effective joining method

Failures of joints during the impacts

Low dissipation of energy during impact
Propagation of impact loads into passenger area
Strain rate sensitivity of adhesive materials
Aging of the adhesive
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Lack of design information

Major requirement for widespread use of adhesives:

Prediction of their performance under impact loading
January 2006

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VELS, Varadin, Croatia

Machine
Ram

Experimental Procedures: IWP

Rubber Washers
for
Damping
Contact

Materials tested
A.A. 5754 (1, 2 & 3 mm) / A.A. 6111 (1 & 2 mm)
XD4600, single part adhesive

Lost
Motion
Device

Test conditions
Room temperature
Test rate of 0.4 - 12 m/s

Ram
Motion

Equipment

Wedge

Servo-hydraulic Instron machine

Strain Gauges
Specimen

Wedge

Bolt

Specimen Grip

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Adhesive
Wedge Retaining Shackle
January 2006

Substrates

PiezoElectric
StaticLoad-Cell
Load-Cell

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Fixed Base

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Experimental Procedures: IWP

Quasi-static crack growth

Transient crack growth

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High speed photography, 4500 f/s of an IWP test exhibited

quasi-static crack growth. Al. Substrates, 1mm thick,
A.A.5754 bonded with XD4600 adhesive and tested at 2.1
m/s, 23 C
January 2006

High speed photography, 4500 f/s of an IWP test exhibited

quasi-static crack growth. Al. Substrates, 2mm thick
A.A.6111 bonded with XD4600 adhesive and tested at 2.1
m/s, 23 C
rd
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Experimental Procedures: IWP

Types of crack growth

Quasi-static (stable)
Transient (unstable)

End

1750

Initial high-peaks region

Plateau region

1500
1250

Transient crack growth

End

2000

Quasi-static crack growth

Quasi-Static Crack Growth (1 mm thick specimen) -5754-0/XD4600 adhesive

Transient Crack Growth (2 mm thick specimen) - 6111-T4/XD4600 adhesive

2250

Force [N]

2500

1000

Initial high-peaks region

No Plateau region

750
500
250

Causes for the initial peaks

Start

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Dynamic effects, from

initial contact between the wedge - specimen
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Crack initiation

Within plateau region: Quasi-static

Transient

January 2006

10

11

12

13

14

15

Time [ms]

Velocity of the crack = Test rate

Crack Velocity > Test rate

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Experimental Procedures: IWP

Quasi-static crack growth: Large plastic deformation

A.A. 5754, 1 mm thick, XD1493, 2 m/s, 23C

Transient crack growth: Low plastic deformation

A.A. 6111, 2 mm thick, XD4600, 2 m/s, 23C

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Numerical Procedures: IWP

Characteristic of IWP numerical systems:

Highly dynamic (stress wave propagation, inertia)
Non-linear numerical systems:
boundary conditions (cohesive zone model, surfaces in
frictional contact)
material properties (elasto-plastic constitutive model)
large deformations
Large numerical systems (high resolution required in the
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contact and the fracture process regions local refinements)
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Can be solved using the FINITE VOLUME METHOD

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Numerical Procedures (Finite Volume Method)

Governing equation for linear momentum (incremental formulation):

#
d (#u& )
1
#b
T
T
$0
dv0 = ! [#S " F + (S + #S )" #F ]" da0 + ! $ 0 dv0
!
# t v0
dt
#t a0
#t
v0
Inertia
forces

Surface
forces

Body
forces

Constitutive relation for elastic-plastic solid (Prandtl-Reuss flow rule):

9 2 S d : !E d
!S = 2 !E + # tr (!E )I $ " p
S
2
E + 3 Seq
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Green strain tensor:

scalar multiplier

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1
1
T
T
T
!E = (I + "!u)# (I + "!u )$ I = ("!u + "!u + "!u # "!u )
2
2

January 2006

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Numerical Simulations (Finite Volume Method)

3D Numerical Model for IWP Test
A.A. 5754, 1 mm thick, XD1493, 2 m/s, 23C

Specified
Displacement
(velocity)

Fixed End
Symmetry Plane

Free End
Numerical crack
tip position

t
tmax
A.A. 6111, 2 mm thick, XD4600, 2 m/s, 23C

GC
Imperial
COD College

COD

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Crack Propagation Event

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Contact Event
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Numerical Simulations (Finite Volume Method)

Traction-separation law (Cohesive Zone Model)

600 s
650 s
700 s
Governs
the local fracture process
Experimentally determined (?)
Widespread and numerically effective method
Predictive model
(crack initiation and propagation results from the analysis)

t
800 s

GC

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Numerical Simulations (Finite Volume Method)

Test parameters:
A.A. 5754, 1 mm thick, XD1493, 2 m/s, 23C

Aluminium arms + adhesive XD4600 + Titanium wedge

Test speed = 2 m/s
Dugdale CZM curve: Gc = 2000 J/m2, max = 50 MPa
Arm thickness = 1, 2 mm
A.A. 6111, 2 mm thick, XD4600, 2 m/s, 23C

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1 mm IWP specimen

16800 Finite Volumes

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Numerical Simulations (Finite Volume Method)

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Numerical Simulations (Finite Volume Method)

Quasi-static crack growth

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Programmed in OpenFoam library

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IWP Test Simulation

Transient crack growth

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Programmed in OpenFoam library

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Conclusions

Finite Volume Method suitable for modelling small scale tests

involving adhesively bonded joints loaded statically and dynamically.

Quasi-static and dynamic crack growth predicted in IWP specimens.

Good transferability of cohesive properties between different tests.
Developing FV elasto-plastic shell model.

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Examples of other FV Simulations

600 s

TDCB
TPB
RCP

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VELS, Varadin, Croatia

Thank you!
vtropsa@vels.hr
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18