Large strain computational modeling of high strain rate phenomena in perforating gun devices by Lagrangian/Eulerian FEM simulations

The present doctoral thesis deals with the study and the analysis of large strain and high strain rate behavior of materials and components. Theoretical, experimental and computational aspects are taken into consideration. Particular reference is made to the modeling of metallic materials, although other kinds of materials are considered as well. The work may be divided into three main parts. The first part of the work consists in a critical review of the constitutive modeling of materials subjected to large strains and high to very high strain rates. Specific attention is paid to the opportunity of adopting so-called strength models and equations of state. Damage and failure modeling is discussed as well. In this part, specific interest is addressed to reviewing the so-called Johnson-Cook strength model, by critically highlighting its positive and negative aspects. One of the main tackled issue consists in a reasoned assessment of the various procedures adoptable in order to calibrate the parameters of the model. This phase is enriched and clarified by applying different calibration strategies to a real case, i.e. the evaluation of the model parameters for a structural steel. The consequences determined by each calibration approach are then carefully evaluated and compared. The second part of the work aims at introducing a new strength model, that consists in a generalization of the Johnson-Cook model. The motivations for the introduction of this model are first exposed and discussed. The features of the new strength model are then described. Afterwards, the various procedures adoptable for the determination of the material parameters are presented. The new strength model is then applied to a real case, i.e. a structural steel as above, and the results are compared to those obtained from the original Johnson-Cook model. Comparing to that, the obtained outcomes show that the new model displays a better capacity in reproducing experimental data. Results are discussed and commented. The third and final part of the work deals with an application of the studied topics to a real industrial case of interest. A device called perforating gun is analyzed in its structural problematics and critical aspects. This challenging application involves the modeling of several typologies of material, large strains, very high strain rate phenomena, high temperatures, explosions, hypervelocity impacts, damage, fracture and phase changes. In this regard, computational applications of the studied theories are presented and their outcomes are assessed and discussed. Several finite element techniques are considered. In particular, tridimensional Eulerian simulations are presented. The obtained results appear to be very promising in terms of the possibilities of a fruitful use in the design process of the device, in particular in order to achieve an optimization of its key features.