DOE/NV/25946--1784

Computational Simulation and Experimental

Study of Plastic Deformation in A36 Steel
during High Velocity Impact
ASME Verification and Validation Symposium, Las Vegas NV, May 22-24, 2013

Presented by:
Brendan OToole, UNLV Professor of Mechanical Engineering

UNLV Collaborators:
Mohamed Trabia, Richard Jennings, Shawoon Roy,
Deepak Somasundarum, Jagadeep Thota

NSTec Collaborators:
Steven Becker, Edward Daykin, Eric Machorro, Timothy Meehan, Robert Hixson, Michael
Pena, Carlos Perez, Nathan Snipe, Aaron Luttman, Kristen Crawford, Steven Gardner

This work was done by National Security Technologies, LLC, under Contract No.
DE-AC52-06NA25946 with the U.S. Department of Energy and supported by the
Site-Directed Research and Development Program. Center for Materials & Structures
 Outline
Objectives
Experimental Description
Computational Methods
Results
Discussion
Recent Experiments
Conclusions

This work was done by National Security Technologies, LLC, under Contract No.
DE-AC52-06NA25946 with the U.S. Department of Energy and supported by the
Site-Directed Research and Development Program. Center for Materials & Structures
 Objectives
Measure target plate back face velocity
during a high velocity impact experiment
where the target material has large
deformations
Use multiple computational methods to
simulate this experiment and compare
predictions with experimental data
Develop a collaborative working relationship
between UNLV and NSTec

This work was done by National Security Technologies, LLC, under Contract No.
DE-AC52-06NA25946 with the U.S. Department of Energy and supported by the
Site-Directed Research and Development Program. Center for Materials & Structures
 Experimental Description:
2-Stage Light Gas Gun
Gunpowder charge
compresses hydrogen
or helium gas
Compressed gas
ruptures a petal valve
Projectile is propelled
down a gun barrel into
an evacuated target
chamber
Current Configuration:
5.6 mm diam. projectile
Velocity: 5 7 km/sec
Manufactured by Physics Applications, Inc., Dayton OH

This work was done by National Security Technologies, LLC, under Contract No.
DE-AC52-06NA25946 with the U.S. Department of Energy and supported by the
Site-Directed Research and Development Program. Center for Materials & Structures
 Target Chamber and Instrumentation

Target and PDV

probe holder

Laser System:
Projectile velocity
Triggering data acquisition
PDV Instrumentation
This work was done by National Security Technologies, LLC, under Contract No.
DE-AC52-06NA25946 with the U.S. Department of Energy and supported by the
Site-Directed Research and Development Program. Center for Materials & Structures
 Experimental Description:
Photonic Doppler Velocimetry (PDV)
Interferometric fiber optic
technique ideally suited for
measuring backface
velocity of target
Velocity is determined by
measuring the Doppler
shift of light reflected from
the moving back surface
Velocity can rise from zero
to peak value in less than 2
microseconds

This work was done by National Security Technologies, LLC, under Contract No.
DE-AC52-06NA25946 with the U.S. Department of Energy and supported by the
Site-Directed Research and Development Program. Center for Materials & Structures
 Experimental Description:
Projectile and Target Description
Projectile
5.60 mm diameter
8.6 mm length
250 mg mass
Lexan (polycarbonate)
Target Plate
A36 Steel
152.4 x 152.4 x 12.7 mm
(6 x 6 x 0.5 in)

This work was done by National Security Technologies, LLC, under Contract No.
DE-AC52-06NA25946 with the U.S. Department of Energy and supported by the
Site-Directed Research and Development Program. Center for Materials & Structures
 Computational Analysis:
Solution Methods
LS-Dyna
Smooth Particle Hydrodynamics (SPH)
Physical domain discretized with particles
Lagrangian collocative method (explicit)
Good for large deformation and hypervelocity impact
CTH
Family of codes developed at Sandia National Laboratories
Multi-material, large deformation, strong shocks
Mass, momentum, and energy conservation equations
solved with a two-step 2nd order Eulerian algorithm

This work was done by National Security Technologies, LLC, under Contract No.
DE-AC52-06NA25946 with the U.S. Department of Energy and supported by the
Site-Directed Research and Development Program. Center for Materials & Structures
 Computational Analysis: Geometry,
Boundary Conditions & Discretization
LS DYNA Analysis Simplifications
2D Axisymmetric
Plate (76.2 mm radius, 12.7 mm
thick)
Free boundary conditions
CTH Analysis
Zone size (Coarse to Fine)
Impact Velocity
6.57, 5.34, and 5.06 km/sec
Simulation run time (~ 5 40 s)

This work was done by National Security Technologies, LLC, under Contract No.
DE-AC52-06NA25946 with the U.S. Department of Energy and supported by the
Site-Directed Research and Development Program. Center for Materials & Structures
 Computational Analysis: Material Models
Johnson-Cook Material model with failure

Constitutive law:

= + 1 + 1
Failure strain:
= 1 + 2 3 1 + 4 1 + 5

where, = flow stress

A, B, C, n, m = constants
= effective plastic strain
D1, D2, D3, D4 = damage constants

= 0 = =

This work was done by National Security Technologies, LLC, under Contract No.
DE-AC52-06NA25946 with the U.S. Department of Energy and supported by the
Site-Directed Research and Development Program. Center for Materials & Structures
 Johnson Cook Material Parameters
Parameters Lexan (Ref # 1) A36 Steel (Ref # 2)
A 75.8 MPa 286.1 MPa
B 68.9 MPa 500.1 MPa
C 0 0.022
M 1.85 0.917
N 1.004 0.2282
Tm 533 K 1811 K
0.344 0.26
0 1 1

Damage Parameters
D1 0 0.403
D2 0 1.107
D3 0 -1.899
D4 0 0.00961
D5 0 0.3

Ref #1: Littlewood, D. J., Simulation of Dynamic Fracture using Peridynamics, Finite Element Modeling, and Contact, Proceedings of the ASME 2010
International Mechanical Engineering Congress and Exposition. Vancouver, Canada, 2010.

Ref #2: Seidt, J.D., Gilat, A., Klein, J.A., Leach, J.R., High Strain Rate, High Temperature Constitutive and Failure Models for EOD Impact Scenarios,
Proceedings of the 2007 SEM Annual Conference and Exposition on Experimental and Applied Mechanics, Springfield, MA, June, 2007.

This work was done by National Security Technologies, LLC, under Contract No.
DE-AC52-06NA25946 with the U.S. Department of Energy and supported by the
Site-Directed Research and Development Program. Center for Materials & Structures
 Computational Analysis: Spall Parameters
Spall failure criteria
- Spalling happens on the rear side of the target.
- Shock wave reaches a free boundary surface and the surface is
subjected to tensile force.
- The material fails when the tensile pressure is above the material strength.

In Ls-Dyna spall failure criteria is given by pressure cut-off (Pmin) value

in *MAT_JOHNSON_COOK.

Lexan: Pmin = - 160 MPa [Ref # 3]

A36 steel: Pmin = - 300 MPa

Ref # 3: Steinberg, D. J. Equation of State and Strength Properties of Selected Materials; UCMRLMA106439; Lawrence
Livermore National Laboratory: Livermore, CA, 1996.

This work was done by National Security Technologies, LLC, under Contract No.
DE-AC52-06NA25946 with the U.S. Department of Energy and supported by the
Site-Directed Research and Development Program. Center for Materials & Structures
 Computational Analysis: Material Models
Gruneisen Equation of State
Pressure for compressed materials:

+
= + +



+ +

Pressure for expanded materials:

= + +

where:
C is the intercept of the shock velocity-particle velocity curve
S1, S2, S3 are dimensionless coefficients of the curve
g0 is the dimensionless Gruneisen gamma
a is the dimensionless first order correction to g0

= 1
0

This work was done by National Security Technologies, LLC, under Contract No.
DE-AC52-06NA25946 with the U.S. Department of Energy and supported by the
Site-Directed Research and Development Program. Center for Materials & Structures
 Computational Analysis: Material Models
Gruneisen Equation of State Parameters

Parameters Lexan (Ref # 4) A36 Steel (Ref # 5)

1190 kg/m3 7890 kg/m3

C0 1933 m/s 4659 m/s

S1 1.42* 1.49

0 0.61 2.17

Ref # 4: Steinberg, D. J. Equation of State and Strength Properties of Selected Materials; UCMRLMA106439; Lawrence
Livermore National Laboratory: Livermore, CA, 1996.

* S value for Lexan was selected from the CTH material library as reference value alters the EOS.

Ref # 5: Elshenawy, T., Li, Q. M., Influences of Target Strength and Confinement on the Penetration Depth of An Oil Well
Perforator, International Journal of Impact Engineering, V. 54, pp 130-137, April 2013.

This work was done by National Security Technologies, LLC, under Contract No.
DE-AC52-06NA25946 with the U.S. Department of Energy and supported by the
Site-Directed Research and Development Program. Center for Materials & Structures
 Results: LS-Dyna Mesh Sensitivity Test #4
Discretization
LS DYNA SPH particle
spacing
- 0.1 mm to 0.5 mm (radial
and axial)
- Simulation with fine particle
spacing (0.1 mm in axial and
radial direction) higher
velocity all the time.
LS DYNA SPH Particle Spacing
300
Experiment # 4
0.1 mm (axial) by 0.1 mm (radial)
250
0.2 mm (axial) by 0.2 mm (radial)
0.1 mm (axial) by 0.3 mm (radial)
0.2 mm (axial) by 0.3 mm (radial)
0.3 mm (axial) by 0.3 mm (radial)
200
V, m/s Impact Velocity = 5.34 km/sec
150
100

CTH mesh zone size

- Coarse (1 mm x 1 mm) 50
- Medium (0.5 mm x 1 mm)
- Fine (0.5 mm x 0.5 mm)
- Medium zone mesh worked 0
0 2 4 6 8 10 12 14 16 18 20
best for CTH simulation.
Time, s

SPH particle spacing 0.3 mm (both axial & radial direction) works best for
LS DYNA simulation

This work was done by National Security Technologies, LLC, under Contract No.
DE-AC52-06NA25946 with the U.S. Department of Energy and supported by the
Site-Directed Research and Development Program. Center for Materials & Structures
 Results Summary:
Experiment vs. LS-Dyna Simulation

Target Velocity, km/s Diameter, mm Penetration, mm Bulge, mm

Test # 1 2 stacked plates 18.06 8.58 4.31

6.569
Sim # 1 Thickness: 6.35 mm each 17.58 9.73 6.14
Test # 2 2 stacked plates 18.82 10.44 2.69
6.458
Sim # 2 Thickness: 6.35 mm each 19.03 6.24 3.00
Test # 3 2 stacked plates 17.39 8.79 5.42
6.513
Sim # 3 Thickness: 6.35 mm each 18.50 6.32 3.03
Test # 4 1 plate 17.01 6.32 2.32
5.338
Sim # 4 Thickness: 12.7 mm 17.02 7.35 3.67
Test # 5 1 plate 16.86 6.89 2.36
5.063
Sim # 5 Thickness: 12.7 mm 15.90 5.04 2.17

This work was done by National Security Technologies, LLC, under Contract No.
DE-AC52-06NA25946 with the U.S. Department of Energy and supported by the
Site-Directed Research and Development Program. Center for Materials & Structures
Results: Simulated Impact Deformations

Test 1: Test 4:
Impact Velocity 6.57 km/sec Impact Velocity 5.34 km/sec

This work was done by National Security Technologies, LLC, under Contract No.
DE-AC52-06NA25946 with the U.S. Department of Energy and supported by the
Site-Directed Research and Development Program. Center for Materials & Structures
 Results: Deformation Progression
CTH: Shear crack growth at the end

LS DYNA: Longitudinal crack growth at the end

This work was done by National Security Technologies, LLC, under Contract No.
DE-AC52-06NA25946 with the U.S. Department of Energy and supported by the
Site-Directed Research and Development Program. Center for Materials & Structures
Results: Final Deformation

CTH LS DYNA

This work was done by National Security Technologies, LLC, under Contract No.
DE-AC52-06NA25946 with the U.S. Department of Energy and supported by the
Site-Directed Research and Development Program. Center for Materials & Structures
Results: Pressure Variation in Simulation
CTH [pressure fringe level in logarithmic scale] [unit: dyne/cm2]

LS DYNA [pressure fringe level in linear scale] [unit: Pa]

This work was done by National Security Technologies, LLC, under Contract No.
DE-AC52-06NA25946 with the U.S. Department of Energy and supported by the
Site-Directed Research and Development Program. Center for Materials & Structures
 Simulation Tools Comparison: LS DYNA vs. CTH
CTH simulation 400
1st peak velocity is Experiment # 1
lower than the 2nd 350
LS-DYNA Simulation
peak velocity. CTH Simulation
Release side velocity 300
profile is similar to the
experimental one but 250
calculates much higher
V, m/s
velocity. 200

LS DYNA simulation
150
Velocity profile is
higher than the 100
experimental one.
Between 12s to 18s, 50
velocity profile shows
a flat plateau which is 0
absent in the 0 5 10 15 20 25 30 35 40
Time, s
experimental velocity
profile.
Better shock physics model is required for both simulation tools.

This work was done by National Security Technologies, LLC, under Contract No.
DE-AC52-06NA25946 with the U.S. Department of Energy and supported by the
Site-Directed Research and Development Program. Center for Materials & Structures
 Results: Backface Velocity vs. Time

400
Experiment (Impact Velocity 6.57 km/s)
350
LS-DYNA (Impact Velocity 6.57 km/s)

300
Experiment (Impact Velocity 5.06 km/s)

LS DYNA (Impact Velocity 5.06 km/s)

250

200
V, m/s

150

100

50

0
0 5 10 15 20 25 30 35 40
Time, s

This work was done by National Security Technologies, LLC, under Contract No.
DE-AC52-06NA25946 with the U.S. Department of Energy and supported by the
Site-Directed Research and Development Program. Center for Materials & Structures
 Discussion Topics
Backface Velocity Predictions
Good overall agreement between experiments and simulation
Some differences just after peak velocity is reached
Deformed Shape of Target
Qualitatively similar
Differences in hole depth and initial fracture patterns
Mesh Sensitivity
Stable results shown on previous slides
Finer mesh in both CTH and LS-DYNA causes velocity
simulations to diverge from experiments
This trend has been discussed in some SPH reference articles.

This work was done by National Security Technologies, LLC, under Contract No.
DE-AC52-06NA25946 with the U.S. Department of Energy and supported by the
Site-Directed Research and Development Program. Center for Materials & Structures
 On-Going Work
Investigate Appropriateness of Material Model
Parameters for A36 Steel and Polycarbonate
Some data difficult to find
Failure behavior will be very sensitive to pressure cutoff
value
Investigate Appropriateness of Material Models for
A36 Steel and Polycarbonate
Johnson Cook and Gruneisen EOS
Is a Phase Change model necessary for A36?
Mesh Sensitivity
Investigate the mesh stability issue further

This work was done by National Security Technologies, LLC, under Contract No.
DE-AC52-06NA25946 with the U.S. Department of Energy and supported by the
Site-Directed Research and Development Program. Center for Materials & Structures
 Microscopy of
Failure Surface:
Is Phase Change
an Issue?

Acknowledgement: Dr. Thomas Hartmann

This work was done by National Security Technologies, LLC, under Contract No.
DE-AC52-06NA25946 with the U.S. Department of Energy and supported by the
Site-Directed Research and Development Program. Center for Materials & Structures
 Microstructure of A36 Steel: Bulk

Typical
microstructure
shows a
combination of
phases:

- Ferrite (white)
- Pearlite (black)

Optical Micrograph of A36 Steel plate

This work was done by National Security Technologies, LLC, under Contract No.
DE-AC52-06NA25946 with the U.S. Department of Energy and supported by the
Site-Directed Research and Development Program. Center for Materials & Structures
Microstructure of A36 Steel: Impact Zone

Microstructures of impact zone shows Bainite mixture (forms when cooled from 727C;
temperature created due to impact ): A probable indication of phase change

This work was done by National Security Technologies, LLC, under Contract No.
DE-AC52-06NA25946 with the U.S. Department of Energy and supported by the
Site-Directed Research and Development Program. Center for Materials & Structures
Microstructure of A36 Steel: Flow

Thickness

Impact zone

A zone of compressed grains with a

mixture of ferrite, pearlite and bainite, is
found along the thickness of the plate
behind the impact zone.

Change of microstructure along the thickness

This work was done by National Security Technologies, LLC, under Contract No.
DE-AC52-06NA25946 with the U.S. Department of Energy and supported by the
Site-Directed Research and Development Program. Center for Materials & Structures
Microstructure of A36 Steel: Spall
Crack
formation due
to grain
tearing

Microstructures showing elongated/stretched

grains in spall crack zone

This work was done by National Security Technologies, LLC, under Contract No.
DE-AC52-06NA25946 with the U.S. Department of Energy and supported by the
Site-Directed Research and Development Program. Center for Materials & Structures
 On-going Plans and Future Work
Multi-Channel PDV to measure velocity at up to 32
discrete points on the back surface of the target.
Potential multi-axis velocity measurement of single point.
High speed video to capture impact and deformation
of target. It could provide independent velocity data
for projectile and spalled particles.
Refined computational simulations to include spall
simulation.
Larger projectiles and symmetric impact (A36 steel
projectile hitting A36 steel target).

This work was done by National Security Technologies, LLC, under Contract No.
DE-AC52-06NA25946 with the U.S. Department of Energy and supported by the
Site-Directed Research and Development Program. Center for Materials & Structures
 MPDV 32-Probe System
and High Speed Video Cameras
High Speed Camera
- Phantom v710 model.
- Maximum frame rate:
1.4 million frame/s.
- Maximum resolution:
1280 x 800 px at 7530
FPS.
- Increasing frame rate,
decreases resolution.
- 300 ns digital exposure.
MPDV System
- Frequency and time division multiplexing.
- Increased capability to acquire data from impact
velocity test > 10 km/s.
- Portable, economical (compare to single-channel 32
PDV system) and rugged.

This work was done by National Security Technologies, LLC, under Contract No.
DE-AC52-06NA25946 with the U.S. Department of Energy and supported by the
Site-Directed Research and Development Program. Center for Materials & Structures
 Recent Experiments:
Chamber Modifications for MPDV and Video

Probe arrangement
Probe holder inside Optical Probes
on target (MPDV)
target chamber

This work was done by National Security Technologies, LLC, under Contract No.
DE-AC52-06NA25946 with the U.S. Department of Energy and supported by the
Site-Directed Research and Development Program. Center for Materials & Structures
 Recent Experiments: High Speed Video
Two cameras [1 for front surface
& 1 for back surface]
Both of the camera captures
video respectively to describe
the experiment.

Front surface camera

- 906,666 frame/s
- 128 x 16 resolution
Back surface camera
- 0.749 s exposure
- 680,000 frame/s
- 32 x 128 resolution
- 1.09 s exposure

Target

This work was done by National Security Technologies, LLC, under Contract No.
DE-AC52-06NA25946 with the U.S. Department of Energy and supported by the
Site-Directed Research and Development Program. Center for Materials & Structures
 Conclusions
Successfully measured target plate back face
velocity during a high velocity impact
experiment.
Used LS-Dyna and CTH to simulate the
experiments with reasonable accuracy.
Developed a collaborative team of more than 15
scientists, engineers, and students that barely
knew each other 12 months ago.

This work was done by National Security Technologies, LLC, under Contract No.
DE-AC52-06NA25946 with the U.S. Department of Energy and supported by the
Site-Directed Research and Development Program. Center for Materials & Structures