A plastic damage model with mixed isotropic-kinematic hardening for low-cycle fatigue in 7020 aluminum

TL;DR

This paper develops a comprehensive plastic-damage model with mixed isotropic-kinematic hardening to accurately predict low-cycle fatigue behavior in 7020 aluminum, validated through experimental and numerical methods.

Contribution

It introduces a novel combined isotropic-kinematic hardening and damage growth model tailored for low-cycle fatigue in aluminum alloys.

Findings

Model accurately predicts fatigue life and damage evolution.

Exponential isotropic hardening improves experimental fit.

Gradient regularization addresses softening-induced ill-posedness.

Abstract

The paper at hand presents an in-depth investigation into the fatigue behavior of the high-strength aluminum alloy EN AW-7020 T6 using both experimental and numerical approaches. Two types of specimens are investigated: a dog-bone specimen subjected to cyclic loading in a symmetric strain-controlled regime, and a compact tension specimen subjected to repeated loading and unloading, which leads to damage growth from the notch tip. Experimental data from these tests are used to identify the different phases of fatigue. Subsequently, a plastic-damage model is developed, incorporating J2 plasticity with Chaboche-type mixed isotropic-kinematic hardening. A detailed investigation reveals that the Chaboche model must be blended with a suitable isotropic hardening and combined with a proper damage growth model to accurately describe cyclic fatigue including large plastic strains up to failure. Multiple back-stress components with independent properties are superimposed, and exponential isotropic hardening with saturation effects is introduced to improve alignment with experimental results. For damage, different stress splits are tested, with the deviatoric/volumetric split proving successful in reproducing the desired degradation in peak stress and stiffness. A nonlinear activation function is introduced to ensure smooth transitions between tension and compression. Two damage indices, one for the deviatoric part and one for the volumetric part, are defined, each of which is governed by a distinct trilinear damage growth function. The governing differential equation of the problem is regularized by higher-order gradient terms to address the ill-posedness induced by softening. Finally, the plasticity model is calibrated using finite element simulations of the dog-bone test and subsequently applied to the cyclic loading of the compact tension specimen.