Lecture 32: Plane Strain Indentation

Analysis using Bound Theorems

Jayadeep U. B.
Dept. of Mechanical Engg., NIT Calicut.
 Introduction
In this lecture, we discuss an application of upper and lower bound
theorems; the specific problem considered is the plane strain
indentation of a rigid perfectly plastic half-space by a flat rigid
punch.
Von Mises yield criterion is assumed for the material.
Refer to the lectures on slipline field theory for simplifications
possible in plane plastic of rigid perfectly plastic materials.
Discontinuities are assumed in the velocity and stress field as per
the requirements of the particular analysis.
Though it is not necessary, we will consider a plane plastic flow
problem for simplicity.

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 Discontinuities in Stress Fields
Sometimes it is convenient to divide the control volume into
different zones, and select statically admissible stress fields in each
zone separately.
There can be discontinuities in stresses at the interfaces of these
stress zones.
Few things are to be always obeyed at these discontinuities:
Within plastically deforming zones, yield criterion is to be satisfied
always.
Newtons third law is to be satisfied at the interface.
Elastic zones are rigid, and hence the stresses cannot be determined
in such zones.

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 Discontinuities in Stress Fields contd.
Stress discontinuity
across a surface under
conditions of plane
strain is shown in fig.
n and must be
continuous across the
interface.
If n and are given,
we have the relation
between t and t
as: t , t = n 2 k 2 2
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 Discontinuities in Velocity Fields
Like the stress fields, kinematically admissible velocity fields also
can have discontinuities.
Often, they are chosen to have discontinuities to conveniently
solve problems.
The discontinuities should be such that the continuity equation
(i.e., the incompressibility condition) is always satisfied.
Hence, the normal component of velocity must be continuous
across any interface.
However, the tangential component can be discontinuous.
Discontinuities must be interpreted as narrow regions with
intense shearing.
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 Upper Bound Analysis
Initial configuration is shown y
in the figure.
Boundary conditions: Flat rigid
(i) Top surface (y = 0) punch vp
x a vx = 0 & v y = vp ( S v ) x
x > a Tx = 0 & Ty = 0 ( SF ) a a
(ii) Surface at infinity Semi-infinite ,rigid
vx = v y = 0 for x = & y =
perfectly plastic material
( Sv )

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 Upper Bound Analysis contd.
Upper bound analysis can be
performed using a kinematically A
admissible velocity field as shown in vp
the figure.
v *
All triangles (B,C,D etc.) are B v* D
equilateral. B v* C D
C
Each triangle moves like a rigid
body, without rotation. So the
velocity in each block is constant: v = const. vi ,i = 0
Velocity b.c.: volume is conserved.
Velocity b.c. at infinity is clearly
satisfied.
Velocity b.c. below punch is
satisfied if: vB* = vp
7
 Upper Bound Analysis contd.
Velocity analysis:
v* v*D/C
Velocity discontinuities must be along the D
60o
discontinuities. v* C
Hence, we can get:
60o
vC* = vp tan 30o & vC* / B = vp sec 30o
vD* vD* / C vC*
o
= o
= o v* B v*B/C
sin 60 sin 60 sin 60 30o
vD* = vp tan 30o & vD* / C = vp tan 30o

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 Upper Bound Analysis contd.
Upper bound theorem:
j j v ijij dV +
D j j dSF

* * * * *
T v dS k v dS T v
Sv V SD* SF

First and third integrals on RHS are equal to zero, since velocity is
constant within a block and specified tractions are absent.
Determining the second integral:
2 Y
*
k v *
dS = *
2 a v *
+ 2 a v *
+ 2 a v *
+ 2 a v *

3
D C / B C D / C D
SD

4avp Y 5 20avp Y
= = 3 Y (using k = )
3 3 3

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 Upper Bound Analysis contd.
Integral on LHS:
T v dS
Sv
j j v = T
Sv
y avg vp dS v = Ty
avg
vp 2a

20a vp 10
Hence we get: 2a vp Ty Y Ty avg Y
avg 3 3

This is an upper limit on the average pressure below the punch,

which is directly related to the punch force required for
indentation.

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 Lower Bound Analysis
The problem considered is same as
that used for upper bound analysis. vp
Boundary conditions are also same. D A
Choose a statically admissible stress field 67.5o 67.5o
as shown in figure. I III 45o
B
It is assumed that the whole region is C I
yielded. II II
In each region, the stress field is I
assumed to be constant.
Hence the equilibrium equations are
readily satisfied.

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 Lower Bound Analysis contd.
Mohrs circle of stress is shown in the figure:

R = Y/3
D A

135o 245o 135o
= 90o
C B

The state of stress on the planes A, B, C and D can be obtained as

shown in the figure.
Normal stress on plane D is obtained as (H.W.): y = 2.788 Y

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 Concluding Remarks
Using lower bound theorem, we can get the pressure below the
punch to be greater than or equal to 2.788Y.
Combining both the bound theorems, we get the inequality:
2.788 Y Ty 3.333 Y
avg

The upper limit can be used to design the system, while the lower
limit can be used to check the extend of overdesigning.
By changing the trail velocity and stress fields, the difference
between the two bounds can possibly be reduced, thereby
improving the estimate of the punch force.

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 References
Chakrabarty, J., Theory of plasticity, Butterworth-
Heinemann.
Hosford, W.F. and Caddell, R.M., Metal Forming,
Cambridge University Press.
Dieter, G.E., Mechanical Metallurgy, McGraw Hill.
Hill, R., The Mathematical Theory of Plasticity, Oxford University
Press.
Johnson ,W. and Mellor, P.B., Plasticity for Mechanical Engineers,
van Nostrand Company Ltd.

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