High Strain Rate Characterization

Of
Engineering Materials

J.D. Rehkopf
Ford Motor Company

Rehkopf FD&E Oct. ‘05

 High Strain Rate Behaviour
Materials can behave quite differently at high rates (crash)
compared to quasi-static (e.g. cargo)

At faster strain rates, plastics can become

much stiffer, stronger, and more brittle.
Eng’g stress

increasing strain rate

Design for crash applications requires

Eng’g strain material behaviour at high rates →
typically 100’s strain per second.
Rehkopf FD&E Oct. ‘05
 High Strain Rate Behaviour

Energy –Absorbing TPO Cladding TPO

left: Slow rate, right: High rate left: Slow rate, right: High rate

Rehkopf FD&E Oct. ‘05

 High Strain Rate Tensile Testing

Why: σ−ε behavior at rates appropriate for the application

How: - Plane Stress State

- Uniform Stress/Strain in gauge
- High Accuracy Measurement of load and strain
- Rates 1 – 800 s-1 at –40°C to +120°C

For: - Direct input for FEA modeling

- Material Development (modulus, strength, ductility)

Rehkopf FD&E Oct. ‘05

 How is the data used?
! FEA sofware material models:
Account for increased strength with increased strain rate

1 ε&
" Johnson-Cook f =1+ ln gives lnε& = pf + (lnD − p)
p D

1
 ε& 
f = 1 +   ⇔ ln(ε& ) = p ln( f − 1) + ln D
p
" Cowper-Symonds
 D

ε& β
σε& =σε& +α(( ) −1)
max max

" Zerrilli-Armstrong o
ε&o
  ε&  
σ = C 0 + C 1 exp  − C 3T + C 4 T ln    + C 5 ε p
n

  ε& o  
Rehkopf FD&E Oct. ‘05
 Material Models
50
T ru e Y ie ld S tre ss (M P a )

45

40
35
30 Test Data
25 Johnson-Cook
Cowper-Symonds
20
Zerilli-Armstrong
15
0 100 200 300 400 500
-1
Strain Rate (s )
Rehkopf FD&E Oct. ‘05
 Conducting Good High Rate Tests

! Initial loading
! “Constant” velocity
! System frequency
! Measurement System
! Time lag
! Filtering
! Specimen Geometry

Rehkopf FD&E Oct. ‘05

 Experimental Setup

• Piezoelectric load cell

• Laser Doppler Extensometer (LDE)

• Slack Adapter to attain speed

pull • Melt Pot for alignment
• LVDT to measure stroke

Rehkopf FD&E Oct. ‘05

 Importance of Test System

SYSTEM RINGING

MINIMAL
SYSTEM RINGING

TIME

Rehkopf FD&E Oct. ‘05

 Laser Doppler Extensometer (LDE)
! Selectable measuring length (gauge), down to 4 mm
! Resolution of Strain ± 1 µm

pull

Rehkopf FD&E Oct. ‘05

 Laser Doppler Extensometer for High Speed
Non-Contact Strain Measurement

motion #1
Laser spot
#1
Strain calculated from
difference between
motion #2 and motion #1

Laser spot motion #2

#2
pull

Rehkopf FD&E Oct. ‘05

 Importance of Accurate Strain Measurement

A,B,C from LVDT

a,b,c from LDE (lasers)
Rehkopf FD&E Oct. ‘05
 High Rate Characterization of Materials
in the Auto Industry

! SAE High Strain Rate Plastics Consortium

" Plastics, Glass Reinforced Plastics

! USAMP/Automotive Composites Consortium –

Energy Management Working Group
" Composites (components primarily)

! A/SP Strain Rate Characterization Committee

" Advanced High Strength Steels

Rehkopf FD&E Oct. ‘05

 SAE HSRPC
Who * ! GM, Ford, Delphi, Visteon, BASF, Basell, Bayer,
DOW, DSM, GE / LNP, LG Chem, Solvay

What ! SAE Consortium : Cooperative Research

Program → SAE Subcommittee
Why ! To develop an industry standard for High Strain
Rate Tensile Testing of Plastics
When ! Formed in 2001 under impetus of UDRI
(Principal Investigator)

How ! Self-Funded by Membership Dues of $10K + $5K

and In-Kind Work

* Toyota paid initial $10K but did not participate

Rehkopf FD&E Oct. ‘05
 HSRPC Main Mission:
To develop an industry standard for High Strain Rate
Tensile Testing of Plastics (incl. LGFR)

Why?
i) to ensure that experimental data is valid and of high quality
ii) to enable sharing of test data across companies and labs
iii) to enhance the understanding of high rate behaviour

Develop better material models for predictive modeling in

crash applications.

Rehkopf FD&E Oct. ‘05

 Non-Reinforced vs GFR Plastics
HDPE, PC/ABS, TPO, GFR-Nylon , LGFR-PP

Rehkopf FD&E Oct. ‘05

 Future Work – Short Term
! Address specimen geometry issues
(particularly for GFR plastics)
! Fiber Orientation

! Geometric Stress Concentration

! Molded vs Machined

! Possible collaboration with ACC-EMWG

Rehkopf FD&E Oct. ‘05

 Plastics Applications

! Fascias/Bumpers ! Door Trim

! Claddings ! Pillar Trim
! Rear Wheel Lips ! IP’s
! Front Wheel Lips ! Air Bag Covers
Rehkopf FD&E Oct. ‘05
 MMIC TPO Cladding: Tensile Test Results

Rehkopf FD&E Oct. ‘05

 MMIC TPO Cladding:
Conclusions ⇒ Material Development
! Color had no effect on the MMIC’s tested

! For MMIC’s and painted TPO, tensile strength

increased significantly with increasing strain rate,
within the high rate region of 1.3 and 2.5 m/s
! MMIC-2 and MMIC-3 had much higher tensile
strength than MMIC-1 and painted TPO
! MMIC-2 and MMIC-3 had much lower failure strains
than the painted TPO or MMIC-1 (< 6 %)
! Cladding and plaques had the same tensile strengths

Rehkopf FD&E Oct. ‘05

 Interior Door Trim (ABS)

Rehkopf FD&E Oct. ‘05

 A/SP Strain Rate Characterization Team

Who * ! DCX, GM, Ford, Steel Suppliers

Labs: UDRI, Los Alamos, ORNL

Why ! To get high strain rate mechanical properties of AHSS for

crash analysis, using existing material models
When ! Formed in 1995

How ! Funded by USAMP, A/SP and In-Kind Work by OEM’s and

Steel Suppliers

What ! Split-Hopkinson Compression, Split-Hopkinson Tension,

Servo-Hydraulic Tension, Hemispherical Impact of Disks,
Double Hinge tests, Conical-column crush (drop tower),
circular columns crush (servo-hydraulic)

* Supplier Partnership has varied over the years.

Rehkopf FD&E Oct. ‘05
 AHSS
Final Report, Proposal Number R-12436 Prepared for Auto/Steel Partnership, Dec. 2000

ASTM D1822 Type L Specimen (Dimensions in inches)

Gauge 9.5 mm long x 3 mm wide

Rehkopf FD&E Oct. ‘05

 Specimen Type #2
Gauge 20 mm long x 10 mm wide

Rehkopf FD&E Oct. ‘05

 AHSS
Final Report, No.: TRP 0038 AISI/DOE Technology Roadmap Program , May 2002

Rehkopf FD&E Oct. ‘05

 AHSS
Final Report, No.: TRP 0038 AISI/DOE Technology Roadmap Program , May 2002

Rehkopf FD&E Oct. ‘05

 Cast Mg and Al for Structural Applications

Rehkopf FD&E Oct. ‘05

 AM60 Results – High Rate
350
300
250
L4 2m/s
Stress (MPa)

200 L5 3m/s

M1 5.7m/s
150 M2 4.5m/s

100 N3 12m/s

F5 2m/s
50
0
0 0.05 0.1 0.15 0.2 0.25
Strain (mm/mm)

Rehkopf FD&E Oct. ‘05

 AM60 Results – Rate Effect
350
300
D2 1mm/s

250 E3a 1mm/s

Stress (MPa)

200 G1 11mm/s

I1 14mm/s
150 I3 10mm/s

100 J5 93 mm/s

K2 150 mm/s
50
0
0 0.05 0.1 0.15 0.2 0.25
Strain(mm/mm)

Rehkopf FD&E Oct. ‘05

 AM60 Results - Variability
350
300 G1 11mm/s, RT

H3 11mm/s, RT
250 H5 18mm/s, RT
Stress (MPa)

200 I1 14mm/s, RT

I2 10mm/s, RT
150 I3a 10mm/s, RT

100 J2 10mm/s, RT

JB4 15mm/s, RT
50 K1 15mm/s, RT

0
0 0.05 0.1 0.15 0.2 0.25
Strain (mm/mm)

Rehkopf FD&E Oct. ‘05

 AM60 Conclusions

! Sample-to-sample variability in tensile behaviour

not atypical of cast materials

! No significant effect of temperature over – 40°C

to + 60°C

! No significant effect of strain rate over 0.0625 s-1

to 480 s-1

Rehkopf FD&E Oct. ‘05

 Cast Aluminum C448
Cast Aluminum C448

300
250
50 mm/s LDE
str e ss (M P a )

200
50 mm/s Extens.
150
500 mm/s
100
4 m/s (~400 s-1)
50
0
0 10 20 30 40
strain %

Rehkopf FD&E Oct. ‘05

 Summary:
High Rate Behaviour of Engineering Materials
Need Data -- Good Experiments are Key
⇑⇓
Initial loading, ringing in load signal, strain measurement

- Incorporate data into existing FE material models

- Assess model with correlation component test
- Develop new models as needed

Rehkopf FD&E Oct. ‘05