Rotating Rubber Wheel

This example contains a simulation of a rotating rubber wheel in plane strain with the MORPH material model formulation [1]. While the rotation is increased, a constant vertical compression is applied to the rubber wheel by a frictionless contact on the bottom. The vertical reaction force is then carried out for the rotation angles. The MORPH material model is implemented as a second Piola-Kirchhoff stress-based formulation with automatic differentiation. The Tresca invariant of the distortional part of the right Cauchy-Green deformation tensor is used as internal state variable, see Eq. (3).

Warning

While the MORPH-material formulation captures the Mullins effect and quasi-static hysteresis effects of rubber mixtures very nicely, it has been observed to be unstable for medium- to highly-distorted states of deformation. An alternative implementation by the method of representative directions provides better stability but is computationally more costly [2], [3].

(1)\[ \begin{align}\begin{aligned}\boldsymbol{C} &= \boldsymbol{F}^T \boldsymbol{F}\\I_3 &= \det (\boldsymbol{C})\\\hat{\boldsymbol{C}} &= I_3^{-1/3} \boldsymbol{C}\\\hat{\lambda}^2_\alpha &= \text{eigvals}(\hat{\boldsymbol{C}})\\\hat{C}_T &= \max \left( \hat{\lambda}^2_\alpha - \hat{\lambda}^2_\beta \right)\\\hat{C}_T^S &= \max \left( \hat{C}_T, \hat{C}_{T,n}^S \right)\end{aligned}\end{align} \]

A sigmoid-function is used inside the deformation-dependent variables \(\alpha\), \(\beta\) and \(\gamma\), see Eq. (4).

(2)\[ \begin{align}\begin{aligned}f(x) &= \frac{1}{\sqrt{1 + x^2}}\\\alpha &= p_1 + p_2 \ f(p_3\ C_T^S)\\\beta &= p_4\ f(p_3\ C_T^S)\\\gamma &= p_5\ C_T^S\ \left( 1 - f\left(\frac{C_T^S}{p_6}\right) \right)\end{aligned}\end{align} \]

The rate of deformation is described by the Lagrangian tensor and its Tresca-invariant, see Eq. (5).

Note

It is important to evaluate the incremental right Cauchy-Green tensor by the difference of the final and the previous state of deformation, not by its variation with respect to the deformation gradient tensor.

(3)\[ \begin{align}\begin{aligned}\hat{\boldsymbol{L}} &= \text{sym}\left( \text{dev}(\boldsymbol{C}^{-1} \Delta\boldsymbol{C}) \right) \hat{\boldsymbol{C}}\\\lambda_{\hat{\boldsymbol{L}}, \alpha} &= \text{eigvals}(\hat{\boldsymbol{L}})\\\hat{L}_T &= \max \left( \lambda_{\hat{\boldsymbol{L}}, \alpha} - \lambda_{\hat{\boldsymbol{L}}, \beta} \right)\\\Delta\boldsymbol{C} &= \boldsymbol{C} - \boldsymbol{C}_n\end{aligned}\end{align} \]

The additional stresses evolve between the limiting stresses, see Eq. (6). The additional deviatoric-enforcement terms [1] are neglected in this example.

(4)\[ \begin{align}\begin{aligned}\boldsymbol{S}_L &= \left( \gamma \exp \left(p_7 \frac{\hat{\boldsymbol{L}}}{\hat{L}_T} \frac{\hat{C}_T}{\hat{C}_T^S} \right) + p8 \frac{\hat{\boldsymbol{L}}}{\hat{L}_T} \right) \boldsymbol{C}^{-1}\\\boldsymbol{S}_A &= \frac{ \boldsymbol{S}_{A,n} + \beta\ \hat{L}_T\ \boldsymbol{S}_L }{1 + \beta\ \hat{L}_T}\\\boldsymbol{S} &= 2 \alpha\ \text{dev}( \hat{\boldsymbol{C}} ) \boldsymbol{C}^{-1} + \text{dev}\left( \boldsymbol{S}_A\ \boldsymbol{C} \right) \boldsymbol{C}^{-1}\end{aligned}\end{align} \]

Note

Only the upper-triangle entries of the symmetric stress-tensor state variables are stored in the solid body. Hence, it is necessary to extract such variables with tm.special.from_triu_1d() and export them as tm.special.triu_1d().

import numpy as np
import tensortrax.math as tm

import felupe as fem


@fem.total_lagrange
def morph(F, statevars_old, p):
    "MORPH material model formulation."

    # right Cauchy-Green deformation tensor
    C = F.T @ F

    # extract old state variables
    CTSn = tm.array(statevars_old[0], like=C[0, 0])
    Cn = tm.special.from_triu_1d(statevars_old[1:7], like=C)
    SAn = tm.special.from_triu_1d(statevars_old[7:13], like=C)

    # distortional part of right Cauchy-Green deformation tensor
    I3 = tm.linalg.det(C)
    CG = C * I3 ** (-1 / 3)

    # inverse of and incremental right Cauchy-Green deformation tensor
    invC = tm.linalg.inv(C)
    dC = C - Cn

    # eigenvalues of right Cauchy-Green deformation tensor (sorted in ascending order)
    λCG = tm.linalg.eigvalsh(CG)

    # Tresca invariant of distortional part of right Cauchy-Green deformation tensor
    CTG = λCG[-1] - λCG[0]

    # maximum Tresca invariant in load history
    CTS = tm.maximum(CTG, CTSn)

    def f(x):
        "Algebraic sigmoid function."
        return 1 / tm.sqrt(1 + x**2)

    # material parameters
    α = p[0] + p[1] * f(p[2] * CTS)
    β = p[3] * f(p[2] * CTS)
    γ = p[4] * CTS * (1 - f(CTS / p[5]))

    LG = tm.special.sym(tm.special.dev(invC @ dC)) @ CG
    λLG = tm.linalg.eigvalsh(LG)
    LTG = λLG[-1] - λLG[0]
    LG_LTG = tm.if_else(LTG > 0, LG / LTG, LG)

    # limiting stresses "L" and additional stresses "A"
    SL = (γ * tm.linalg.expm(p[6] * LG_LTG * CTG / CTS) + p[7] * LG_LTG) @ invC
    SA = (SAn + β * LTG * SL) / (1 + β * LTG)

    # second Piola-Kirchhoff stress tensor
    S = 2 * α * tm.special.dev(CG) @ invC + tm.special.dev(SA @ C) @ invC

    try:  # update state variables
        statevars_new = np.stack(
            [CTS.x, *tm.special.triu_1d(C).x, *tm.special.triu_1d(SA).x]
        )
    except:
        # not possible (and not necessary) during AD-based hessian evaluation
        statevars_new = statevars_old

    return S, statevars_new


umat = fem.MaterialAD(
    morph,
    p=[0.039, 0.371, 0.174, 2.41, 0.0094, 6.84, 5.65, 0.244],
    nstatevars=13,
    # parallel=True,
)

Note

The MORPH material model formulation is also available in FElupe, see morph.

The force-stress curves are shown for uniaxial incompressible tension cycles.

ux = fem.math.linsteps([1, 1.5, 1, 2, 1, 2.5, 1, 2.5], num=(10, 10, 20, 20, 30, 30, 30))
ax = umat.plot(
    ux=ux,
    bx=None,
    ps=None,
    incompressible=True,
)

A mesh is created for the wheel with \(r=0.4\) and \(R=1\).

mesh = fem.mesh.Line(a=0.4, n=6).revolve(37, phi=360)
mesh.update(points=np.vstack([mesh.points, [0, -1.1]]))
x, y = mesh.points.T
mesh.plot().show()

Static Scene

Interactive Scene

A quad-region and a plane-strain displacement field are created. Mesh-points at \(r\) are added to the move-boundary condition. The displacements due to the rotation of the wheel are evaluated for each rotation angle. The center-point of the bottom-edge is moved vertically upwards by 0.2 to enforce a vertical reaction force in the rubber wheel.

Note

Try to simulate more rotation angles and obtain the vertical reaction force of the wheel, e.g. run two full rotations of the wheel with angles_deg = fem.math.linsteps([0, 360, 720], num=[18, 18]).

region = fem.RegionQuad(mesh)
field = fem.FieldContainer([fem.FieldPlaneStrain(region, dim=2)])

mask = np.isclose(np.sqrt(x**2 + y**2), 0.4)
boundaries = {
    "move": fem.dof.Boundary(field[0], mask=mask),
    "bottom-x": fem.dof.Boundary(field[0], fy=-1.1, value=0.0, skip=(0, 1)),
    "bottom-y": fem.dof.Boundary(field[0], fy=-1.1, value=0.2, skip=(1, 0)),
}

angles_deg = fem.math.linsteps([0, 120], num=6)
move = []
for phi in angles_deg:
    center = mesh.points[boundaries["move"].points]
    center_rotated = fem.mesh.rotate(
        points=center,
        cells=None,
        cell_type=None,
        angle_deg=phi,
        axis=0,
        center=[0, 0],
    )[0]
    move.append((center_rotated - center).ravel())

A nearly-incompressible solid body is created for the rubber. At the bottom, a frictionless contact edge is created. Both items are added to a step, which is further evaluated in a job. The reaction forces are plotted for the successive rotation angles of the wheel.

solid = fem.SolidBodyNearlyIncompressible(umat, field, bulk=5000)
bottom = fem.MultiPointContact(
    field,
    points=np.arange(mesh.npoints)[np.isclose(np.sqrt(x**2 + y**2), 1.0)],
    centerpoint=-1,
    skip=(1, 0),
)
step = fem.Step(
    items=[solid, bottom], ramp={boundaries["move"]: move}, boundaries=boundaries
)

job = fem.CharacteristicCurve(steps=[step], boundary=boundaries["move"])
job.evaluate(tol=1e-1)

fig, ax = job.plot(
    x=angles_deg.reshape(-1, 1),
    yaxis=1,
    yscale=-1,
    xlabel=r"Rotation Angle $\theta$ in deg $\longrightarrow$",
    ylabel=r"Force $|F_y|$ in N $\longrightarrow$",
)
ax.set_xticks(angles_deg[::6])

The resulting max. principal values of the Cauchy stresses are shown for the final rotation angle.

solid.plot(
    "Principal Values of Cauchy Stress",
    plotter=bottom.plot(color="black", line_width=5, opacity=1.0),
    project=fem.topoints,
).show()

Static Scene

Interactive Scene

References

[1] (1,2)

D. Besdo and J. Ihlemann, “A phenomenological constitutive model for rubberlike materials and its numerical applications”, International Journal of Plasticity, vol. 19, no. 7. Elsevier BV, pp. 1019–1036, Jul. 2003. doi: 10.1016/s0749-6419(02)00091-8.

[2]

M. Freund, “Verallgemeinerung eindimensionaler Materialmodelle für die Finite-Elemente-Methode”, Dissertation, Technische Universität Chemnitz, Chemnitz, 2013.

[3]

C. Miehe, S. Göktepe and F. Lulei, “A micro-macro approach to rubber-like materials - Part I: the non-affine micro-sphere model of rubber elasticity”, Journal of the Mechanics and Physics of Solids, vol. 52, no. 11. Elsevier BV, pp. 2617–2660, Nov. 2004. doi: 10.1016/j.jmps.2004.03.011.