XFEM Simulation of Tensile and Fracture Behavior of Ultrafine-Grained Al 6061 Alloy

In the present work, the tensile and fracture behavior of ultra-fine grained (UFG) Al 6061 alloy was simulated using extended finite element method (XFEM). UFG Al 6061 alloy processed by cryorolling (CR) and accumulative roll bonding (ARB) was investigated in this work. Numerical simulations of two-dimensional and three-dimensional models were performed in Abaqus 6.14 software using an elastic-plastic approach, and the results obtained were validated with the experimental results. The specimens corresponding to the three-point bend test, compact tension test with center crack, and double edge cracks were analyzed using XFEM (eXtended Finite Element Method) approach. In XFEM, the partition of unity (PU) was used to model a crack in the standard finite element mesh. The tensile and fracture properties obtained from the simulation were in tandem with the experimental data. UFG Al alloy showed higher tensile strength and fracture toughness compared to their bulk solution treated counterparts. Fracture toughness was measured in terms of stress intensity factor and J integral. In CR Al alloys, with increasing thickness reduction, an increase in stress intensity factor and a decrease in the J integral was observed. This behavior is attributed to the increase in strength and decrease in ductility of CR samples with increasing thickness reduction. In ARB Al alloys, the strength and ductility have increased with an increase in number of cycles. It also revealed an increase in both the stress intensity factor and J integral in ARB processed Al alloys with increase in number of cycles, as evident from XFEM simulation results.

Automated summary

In this study, the tensile and fracture behavior of UFG Al 6061 alloy was simulated using XFEM, showing that UFG Al alloy exhibits higher tensile strength and fracture toughness compared to their bulk solution treated counterparts. For CR Al alloys, a decrease in thickness leads to an increase in stress intensity factor and a decrease in the J integral, while for ARB Al alloys, an increase in strength and ductility was observed with an increase in the number of cycles. XFEM simulation results also indicated an increase in both stress intensity factor and J integral with an increase in the number of cycles for ARB processed Al alloys.