FACTA UNIVERSITATIS
Series: Mechanical Engineering Vol. 16, No 1, 2018, pp. 41 - 50
https://doi.org/10.22190/FUME171229010D
© 2018 by University of Niš, Serbia | Creative Commons Licence: CC BY-NC-ND
Original scientific paper
SIMULATION OF FRACTURE USING A MESH-DEPENDENT
FRACTURE CRITERION IN THE DISCRETE ELEMENT METHOD
UDC 539.4, 519.6
Andrey Dimaki1, Evgeny Shilko1, Sergey Psakhie1, Valentin Popov2
1Institute of Strength Physics and Materials Science SB RAS, Tomsk, Russia
2Berlin University of Technology, Berlin, Germany
Abstract. Recently, Pohrt and Popov have shown that for simulation of adhesive contacts
a mesh dependent detachment criterion must be used to obtain the mesh-independent
macroscopic behavior of the system. The same principle should be also applicable for the
simulation of fracture processes in any method using finite discretization. In particular, in
the Discrete Element Methods (DEM) the detachment criterion of particles should depend
on the particle size. In the present paper, we analyze how the mesh dependent detachment
criterion has to be introduced to guarantee the macroscopic invariance of mechanical
behavior of a material. We find that it is possible to formulate the criterion which
describes fracture both in tensile and shear experiments correctly.
Key Words: Fracture, Mesh-Dependence, Discrete Element Method, Particle Size
1. INTRODUCTION
Since the work of Hertz [1] it is well-known that stress distribution in a contact area is
not uniform. Stress distribution in the contact between an elastic half-space and sharp-
edged rigid or elastic counter-bodies of a different shape (e.g. a cylinder, frustum etc.)
tends to infinity in a vicinity of the contact area boundary [2, 4-6]. In reality, stresses at
the contact area boundary never achieve infinite values due to surface roughness and/or
plastic deformation [3]. Nevertheless, these stresses are several times higher than in the
center of the contact area.
The presence of high stress concentrations near contact patch boundaries, notches etc.
leads to nucleation of cracks on different scales [7, 8]. In order to describe conditions of
fracture in the regions with heterogeneous stress/strain fields, non-local fracture criteria
Received December 29, 2017 / Accepted February 05, 2018
Corresponding author: Andrey V. Dimaki
Institute of Strength Physics and Materials Science SB RAS, 634055, Tomsk, Russia
[email protected]sc.ru
42 A. DIMAKI, E. SHILKO, S. PSAKHIE, V. POPOV
have been developed. Perhaps one of the most popular nonlocal fracture criteria is
Novozhilov fracture criterion [9] which reads
1
10
1()
d
yc
x dx
d
, (1)
where σc is the strength of a homogeneous material under uniaxial tension without stress
concentrators, σy(x) is the maximum normal stress, x axis corresponds to a “most probable”
direction of crack propagation, d1 is a material constant having a dimensionality of length.
Similar forms of nonlocal criterion (1) were used in [10] for composites and in [11] for
notched samples. Another way of taking into account stress concentrators is to include
both absolute value of stress (either maximal or average value) and its gradient in a crack
processing zone:
0
( , / )
ec
f L L
, (2)
where L0 is a characteristic size of material structure elements, Le is a size of stress
concentration zone [12]. In the framework of this approach the size of stress concentration zone
depends on a local stress gradient: Le = Le(grad(σ)).
When developing a numerical model of the contact, or, more generally, of a sample
with stress concentrators, it is necessary to adequately describe crack nucleation conditions
since they significantly depend on stress distribution approximation accuracy that is
determined, in turn, by mesh size. Correspondingly, variation of the mesh size may have
influence on the values of mechanical characteristics of the simulated samples, e.g. their
compressive/tensile strength, etc.
The traditional way of describing heterogeneous stress/strain fields, based on mesh
refinement, is not applicable to problems where “quasi-infinite” local values of stresses
can occur. These problems include friction and wear, contact problems with punches
having sharp edges, etc. In this case, in order to adequately describe fracture in numerical
models, nonlocal fracture criteria of types (1) and (2) are widely used. Examples of their
applications in the finite-element method (FEM) can be found in papers [13, 14] and in
many others.
Recently, Popov and Pohrt have suggested a mesh-dependent detachment criterion in
the boundary element method (BEM) for a normal adhesive contact problem of linearly
elastic and power-law graded elastic materials [15-17]. The main idea of the suggested
approach is a modification of local ultimate stress value instead of stress field correction.
The given criterion is local and it allows adequate descriptions of a normal contact
between an elastic half-space and a rigid indenter in the presence of adhesive forces.
Despite a wide application of non-local and mesh size dependent fracture criteria in
continuum-based approaches like FEM, the size-dependent fracture criteria in DEM still
remain much less studied [18]. In the paper we study the relation between tensile and
shear contact strength and a discrete element size. Hereinafter the term “contact strength”
means a maximal value of a force divided to the contact square that is required to detach
the contacting bodies. Based on the obtained results, we suggest a mesh-dependent local
fracture criterion which allows us to overcome the mentioned problem, namely to avoid
dependence of the contact strength on element size.
Simulation of Fracture Using a Mesh-Dependent Fracture Criterion in a Discrete Element Method 43
2. FORMULATION OF THE PROBLEM
Let us consider a contact between an elastic half-space and an elastic punch, which are
initially bonded (see Fig. 1). We study dependence of the contact tensile strength on element
size d. A displacement with constant vertical velocity is applied to the upper layer of the
punch while the lower layer of the half-space is fixed in vertical direction. Horizontal
motions of elements of the top boundary of the punch and the bottom boundary of the half-
space are allowed. The materials of the punch and the half-space are considered linearly
elastic. We used the Movable Cellular Automaton method (MCA) [19-21] which is a DEM
family representative with multi-particle distinct element formulation of the equations of
elasticity and motion.
Fig. 1 Schematic of the simulated sample; element size d=0.001 m
The elastic modulus of the half-space was Ehalf-space = 200 GPa, the elastic modulus of
the punch Epunch was varied in a certain range in order to perform a parametric study of the
problem. The values of the Poisson’s ratios were νpunch = νhalf-space = 0.3. The value of the
ultimate stress in von Mises fracture criterion was YMises = 200 MPa that leads to relatively
small values of strains in the punch and the substrate at the moment of fracture. The strain
rate was of the order of
≈ 0.3 sec-1 that provides a quasi-static loading regime.
We used a finite-size punch and a large counter-body which imitates a half-space.
Evidently, the boundary conditions produce a contribution to the values of sample strength
obtained during simulations. In order to diminish influence of the boundary conditions we
studied the convergence of the strength value when thickness and height of a punch and a
counter-body simulating a half-space increase. The values of thickness H and width W of
the counter-body greater than five widths of the punch 2a0 guarantee convergence of the
value of the tensile strength and, consequently, the absence of the boundaries’ influence.
Punch height h>3a0 guarantees tensile strength being independent of h. The following
values of the sizes of the punch and the “half-space” were used in the calculations
described below: a0=0.01 m, h=0.03 m, H=0.125 m, W=0.1 m. The closed package of
44 A. DIMAKI, E. SHILKO, S. PSAKHIE, V. POPOV
discrete elements was used. It should be noted that the use of a close-packed ensemble of
circular discrete elements leads to the appearance of an "artificial roughness" on the boundaries
of the sample (see Fig. 1).
2.1. Description of the discrete element model
In the framework of MCA a solid body is considered as an ensemble of interacting
particles (elements) of finite size. Contacts of interacting pairs of elements are considered
to be initially bonded that simulates a consolidated solid, while the contacts between
crack faces are considered as unbonded. Switching between bonded and unbounded states
occurs when a given fracture or linkage criterion is satisfied.
Interaction between the contacting elements (either bonded or unbonded) is realized
through their common plane faces. The evolution of an ensemble of discrete elements is
defined by a numerical solution of the system of Newton-Euler equations of motion:
2
21
1
()
i
i
Nn
ii
i i ij ij
j
N
i
i ij
j
d r dv
m m F F
dt
dt
dM
Jdt
, (3)
where
i
r
,
i
v
and
i
are the radius-vector, velocity vector and angular velocity of discrete
element i, mi is the element mass, Ji is the moment of inertia of an equivalent disc or sphere,
n
ij
F
and
ij
F
are the forces of central (normal) and tangential interaction between element i
and its neighbor j, and
ij ij ij ij
M q n F
is the torque. Equation (3) describes translational and
rotational motion of the discrete elements having a finite size. Both the constituents (
n
ij
F
and
ij
F
) of the interaction force between discrete elements i and j in Eq. (3) include potential
(
np
ij
F
and
p
ij
F
) and dissipative/viscous (
nv
ij
F
and
v
ij
F
) contributions [19]:
n np nv
ij ij ij
pv
ij ij ij
F F F
F F F
. (4)
As follows from Eq. (4), the value of torque
ij
M
includes both potential and dissipative
constituents.
The major features of the MCA method are the approximation of a homogeneous
stress-strain distribution in a simply deformable element and the postulated form of the
relation for the reaction force of a discrete element in response to the action of its
neighboring element.
In the simply deformable element approximation the state of a discrete element is
determined by average stress tensor
i
and average strain tensor
i
[21] calculated
based on the specific values of normal and tangential forces in interacting pairs of discrete
elements. Tensors
i
and
i
are assumed to be related by an assigned constitutive law.
This law determines a relationship between force and spatial interaction parameters for a
pair of elements. The MCA method postulates a structural form of relations for the central
and tangential interaction forces of discrete elements. We have used a generalized Hooke’s law
Simulation of Fracture Using a Mesh-Dependent Fracture Criterion in a Discrete Element Method 45
for isotropic materials as constitutive relation
()
ii
for the elastic response of a simply
deformable discrete element.
The developed approach allows using multi-parametric failure criteria (von Mises,
Mohr–Coulomb, Drucker–Prager and others) for simulation of bond breaking between the
pairs of interacting discrete elements. In this paper we used the von Mises fracture criterion in
the following form:
2 2 2 2
1( ) ( ) ( ) 6
2xx yy yy zz zz xx xy Mises
Y
, (5)
written for a pair of interacting discrete elements.
3. RESULTS OF SIMULATION
There is a well-known analytic solution for the normal pressure distribution under an
elastic flat punch contacting with an elastic half-space [3, 6]. This solution suggests the
presence of peaks of normal pressure near the boundary of the contact area. Height and,
more generally, shape of these peaks depend on curvature of the corners of the punch, the
relation of elastic moduli of the punch and the half-space, the roughness and the coefficient
of friction between the contacting bodies, etc. In any case, these peaks are much higher than
the pressure on the axis of the punch. This fact leads to a curious result at the DEM
simulation of detachment of a punch from a half-space. Namely, tensile strength σt of a
contact between a punch and half-space becomes lower with decrease of the diameter of a
discrete element in accordance with the power law:
0
0
s
tt
d
d
, (6)
where σt0 is a parameter having the dimensionality of stress, d is a discrete element size,
d0 is a normalizing constant and s is the exponent. The dependencies of tensile strength on
element size for different relations of elastic moduli of the punch and the half-space
e = Epunch / Ehalf-space are shown in Fig. 2.
Evidently, the upper limit of the element size is a punch size and the lower limit tends
to zero. As one can see from Fig. 2, there is no convergence (at least, asymptotic) of the
values of tensile strength on the lower limit of element size. This means the formulation of
the numerical model is physically inadequate and must be improved in a way guarantying
convergence of the results of simulation with decreasing of an element size. It is necessary
to note the fact that the mentioned effect of element size dependence of tensile contact
strength holds for different types of fracture criteria (von Mises, Drucker-Prager, detachment
at a given value of normal tensile stress etc). Also this effect exists when a quadratic
package of elements is used.
46 A. DIMAKI, E. SHILKO, S. PSAKHIE, V. POPOV
Fig. 2 Dependencies of the contact tensile strength on the element size
for the size independent local detachment criterion
In order to study the influence of the direction of loading, we carried out a series of
calculations in which shear loading with constant horizontal velocity was applied to the
top layer of the punch, while it was fixed in vertical direction. It was found that shear
strength of the contact between the punch and the half-space depends on the element size
in the same manner as the tensile strength discussed above (see Fig. 3).
Shear strength of the contact obeys to the power law
0
0
q
shear
d
d
, (7)
where τ0 has the dimension of stress, q is the exponent determining the slope of the
logarithmical dependence of shear strength on the element size. Based on the analysis of
the dependencies shown in Figs. 2 and 3 we obtained the following estimate of the exponents
from Eqs. (6) and (7) for e = 1:
0.4 0.01sq
. (8)
Fig. 3 Shear strength of a contact versus element size
Simulation of Fracture Using a Mesh-Dependent Fracture Criterion in a Discrete Element Method 47
The estimates of s and q for different values of e are summarized in Table 1. It is evident
that the highest discrepancy between the values of exponents s and q takes place for e = 10
(the stiffest punch); in other cases the difference between them does not exceed few percent.
This demonstrates universality of the obtained dependencies of strength on element diameter
and their applicability to construction of a mesh-dependent fracture criterion.
Table 1 Values of s and q for different values of e = Epunch / Ehalf-space
E
Tension
Shear
S
q
0.2
0.3
0.31
1
0.4
0.41
10
0.44
0.47
4. DISCUSSION
The obtained element size dependence originates from the non-uniform stress
distribution in the contact area with high values of stresses near boundaries. The peaks of
stresses take place for all components of stress tensor and for equivalent (von Mises)
stress which determines crack formation due to the fact that the von Mises fracture
criterion was used in the performed calculations. At that, the smaller an element size the
higher the peaks and the earlier fracture occurrence (see Fig. 4).
Based on the hypothesis that the power-law dependence of contact strength on element
size has nearly the same value of the exponent as the contact stress distribution, we have
carried out the following test. In the paper [6] an approximation for normal stress
distribution has been proposed:
22
( ) ( , )/( )p x FM a a x
, (9)
where F – total force, applied on punch, M(λ, a) – a non-dimensional weight function, x –
spatial coordinate along the contact patch measured from the punch center, λ – the
exponent (see also, [23]). There is an analytic solution for λ, obtained by Rao [3] for a
punch with an arbitrary angle at the corner θ:
2
tan(1 ) (1 )sin2 sin2(1 ) 1 cos2(1 ) (1 ) (1 cos2 )e
. (10)
For a cylindrical punch which is rectangular in 2D cross-section θ = π / 2 and Eq. (10)
simplifies to
2
tan(1 ) sin(1 ) 1 cos(1 ) 2(1 ) 0e
. (11)
It is interesting that Eqs. (10) and (11) do not contain Poisson’s ratios of a punch and
a half-plane that means, in particular, that a value of λ is the same for plane stress and
plane strain conditions [3].
48 A. DIMAKI, E. SHILKO, S. PSAKHIE, V. POPOV
Fig. 4 Spatial distributions of the von Mises stress on the surface
of the half-space for different values of element size
Having applied Eq. (9) for approximation of the von Mises stress distribution in the
contact area, we obtained the estimation λ ≈ 0.39 (see Fig. 5). This value agrees well with
the values of exponents s and q, which enter Eqs. (6) and (7) correspondingly. The given
fact demonstrates that the character of the dependence of contact strength on element size
is determined by stress distribution in a contact area.
The analytic estimate of parameter λ, calculated by means of solution of Eq. (11), is
λ ≈ 0.226 for e = 1. The discrepancy between the given analytic estimate and the value of
λ, obtained on the basis of approximation of numerical simulation results (see. Fig. 2), has
the following reason: we applied Eq. (9) for approximation of the von Mises stress
distribution in the contact area although the given equation was initially obtained for
description of normal stress distribution, taking no account of squeezing and bending of a
material in the contact area and surroundings.
Fig. 5 Normalized dependence of the von Mises stress under the punch
and its analytic approximation Epunch = Ehalf-space.
Simulation of Fracture Using a Mesh-Dependent Fracture Criterion in a Discrete Element Method 49
Based on the results described above, we suggest an equation for the value of ultimate
stress in the von Mises failure criterion:
()
0
0
()
e
Mises
d
Y d Y d
, (12)
where λ(e) is a function of the relation e = Epunch / Ehalf-space, the value of Y0 depends on
material strength, ratio e, contact size, etc. Obtaining closed-form equations for λ(e) and Y0
requires additional research. Application of Eq. (12) in fracture criterion (5) allows obtaining
almost the same values of tensile strength of samples with different element size (see Figs.
6a and 6b). One can see that the loading diagrams of samples under tension are almost
identical (Fig. 6b). A distinction between them is conditioned by a small difference of
stiffness of samples with different element size. The deviation of tensile stress from its
sample mean value does not exceed two percent (Fig. 6b).
It is a well-known fact that macroscopic plasticity of brittle solids is often a consequence
of microscopic failures nucleation, motion and healing [22]. This is one of the facts
underlining similarity and interconnectedness of plasticity and fracture phenomena. From
this point of view it is obvious to make an assumption about an existence of mesh-dependent
criterion of plasticity. The latter is the topic for a future work.
Fig. 6 a) The diagrams of tensile loading for samples with different element size;
b) The deviation of tensile strength from its mean value vs. element size Epunch = Ehalf-space
5. CONCLUSIONS
We have carried out the numerical simulation of a contact between an elastic punch
and a half-space within the discrete element method. We have shown that the use of local
detachment criterion without accounting for a discrete element size leads to a power-law
dependence of contact strength on element size. The value of exponent in this dependence
is approximately equal to 0.4±0.01 both for tensile loading and for shearing.
Based on the obtained results we have proposed a mesh-dependent fracture criterion
which explicitly includes the discrete element size. The suggested fracture criterion provides
almost size-independent values of tensile and shear strength for a punch detachment from a
half-space. Although the obtained fracture criterion is not universal, it demonstrates a
50 A. DIMAKI, E. SHILKO, S. PSAKHIE, V. POPOV
perspective of development of discrete-element models for brittle and elastic-plastic
materials with stress concentrators.
Acknowledgements: This work was supported in parts by the Fundamental Research Program of
the State Academies of Science for 2013-2020 (Russia) and by the Deutscher Akademischer
Austauschdienst (DAAD).
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