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The purpose of this study is to develop a normal contact stiffness (NCS) model among three disks of the assembled rotor system, which systematically considers the friction coefficient, the asperities interaction and the elastoplastic contact regime.

Based on the revised fractal theory, considering the friction effect, the elastoplastic contact regime and the asperities interaction in a simple way, the total NCS among three disks of the rod-fastening rotor bearing system is established. Effects of fractal dimension and roughness, friction coefficient, asperities interaction and material properties on the normal stiffness are investigated by simulations and the relevant comparisons are given for examining the reasonability of the proposed model.

NCS will decrease when asperities interaction and friction are included. As the load increases, the influences of asperities interaction and friction on stiffness become serious. NCS will be enhanced when the elastoplastic regime is considered.

A comprehensive NCS model is developed. It provides a theoretical basis for the modeling of the NCS for multi-interfaces.

This paper proposes a unified original general framework, designed to theoretically develop and to extremely easily implement elastoplastic constitutive laws defined in the so called two-invariants space, both in small and finite strain regime.

A general return mapping algorithm is proposed, and particularly a standard procedure is developed to compute the two algorithmic tangent operators, required to solve the Newton–Raphson scheme at the local and global level and thus cast the elastoplastic algorithm within a FEM code.

This work demonstrates that the proposed procedure is fully general and can be applied whatever is the elastic law, the yield surface, the plastic potential function and the hardening law. Several numerical examples are reported, not only to demonstrate the accuracy and robustness of the algorithm, but also explain how to use this general algorithm also in other applications.

The proposed algorithm and its numerical implementation into a FEM code is new and original. The usefulness and the value of the algorithm is twofold: (1) it can be implemented in a small and finite strain simulation FEM code, in order to handle different types of constitutive laws in the same modular way, thus fully leveraging on modern object-oriented coding approach; (2) it can be used as a framework to develop (and then to implement) new constitutive models, since the researcher can simply define the relevant functions (and its main derivatives) and automatically get the numerical algorithm.

This study aims to investigate the contact behavior of nominal curved surfaces with random roughness.

A deterministic model was applied to investigate the contact behavior. Numerical calculations were conducted on Gaussian and fractal profiles under a range of loading conditions. The deformation behavior is characterized in terms of three regimes including the elastic, elastoplastic and plastic regimes.

A linear relationship was observed between the real contact areas and normal loads, which is mainly governed by the plastic deformation. Surface roughness changes contact behavior by influence the transition of deformation regimes. Rougher surfaces generally demonstrate higher saturated plastic ratios.

The contact behavior of nominally curved surfaces with random roughness is understood in terms of the evolution of real contact areas and plastic ratios.

The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-05-2019-0190.

An efficient boundary element method (BEM) formulation for three‐dimensional elastoplasticity is presented in this paper. The BEM formulation for nonlinear problems requires discretization of the surface as well as part of the volume. In this paper nine‐noded quadrilateral elements are used for modelling the surface and 27‐noded brick elements for the volume. Particular attention is paid to the accurate evaluation of the Cauchy principal value volume integrals appearing in the interior stress calculations. An explicit initial strain formulation is used to satisfy the non‐linearity. The accuracy of the proposed method is demonstrated by solving a number of benchmark problems.

This paper aims to propose a normal and tangential contact stiffness model to investigate the contact characteristics between rough surfaces of machined joints based on fractal geometry and contact mechanics theory considering surface asperities interaction.

The fractal geometry theory describes surface topography and Hertz contact theory derives the asperities elastic, elastic-plastic and plastic contact deformation. The joint normal and tangential contact stiffness are obtained. The experiment method for normal and tangential contact stiffness are introduced.

The relationship between dimensionless normal contact load and dimensionless normal and tangential contact stiffness are analyzed in different plasticity index. The results show that they are nonlinear relationships. The normal and tangential contact stiffness are obtained based on theoretical and experimental methods for milling and grinding machined specimens. The results indicate that the present model for the normal and tangential contact stiffness are consistent with experimental data, respectively.

The normal and tangential contact stiffness models are constructed by using the fractal geometry and the contact mechanics theory considering surface asperities interaction, which includes fully elastic, elastic-plastic and fully plastic contacts deformation. The present method can generate a more reliable calculation result as compared with the contact model no-considering asperities interaction.

Fatigue crack growth models based on elastic‐plastic stress‐strain histories at the crack tip region and strain‐life damage models have been proposed. The UniGrow model fits this particular class of fatigue crack propagation models. The residual stresses developed at the crack tip play a central role in these models, since they are applied to assess the actual crack driving force. This paper aims to assess the performance of the UniGrow model based on available experimental constant amplitude crack propagation data, derived for several metallic materials from representative Portuguese bridges. It also aims to discuss key issues in fatigue crack growth prediction, using the UniGrow model, in particular the residual stress computation and the suitability of fatigue damage rules.

The UniGrow model is assessed using data derived by the authors for materials from Portuguese riveted metallic bridges. Strain‐life data, from fatigue tests on smooth specimens, are used to propose a convenient fatigue damage model. Predicted crack growth rates are compared with experimental crack propagation data obtained by authors using fatigue tests on compact tension specimens. Since the UniGrow model is a residual stress‐based propagation model, elastoplastic finite element analysis is proposed for comparison with the analytical approach implemented in the original UniGrow model.

The use of the Smith‐Watson‐Topper damage parameter overestimates the stress R‐ratio effects on crack propagation rates, mainly if the material shows crack propagation rates with small to moderate sensitivity to stress R‐ratio, which is the case of the materials under investigation in this paper. Alternatively, the application of the Coffin‐Manson damage law leads to consistent fatigue crack growth predictions for the investigated range of positive stress R‐ratios. The stress R‐ratios effects may be solely attributed to the residual stresses. Their estimation, using an analytical approach, may lead to inconsistent results, which is demonstrated by an alternative elastoplastic finite element analysis.

Contributions for more accurate predictions of fatigue crack propagation rates, for several stress ratios, using a strain‐based approach is proposed. This approach is valuable since it may be used to reduce the time consuming and costly fatigue crack propagation tests. Furthermore, the proposed approach shows potential for an unified crack initiation and propagation approach.

The objective of this work is to develop an element technology to recover the plane stress response without any plane stress specific modifications in the large strain regime. Therefore, the essential feature of the proposed element formulation is an interface to arbitrary three‐dimensional constitutive laws. The easily implemented and computational cheap four‐noded element is characterized by coarse mesh accuracy and the satisfaction of the plane stress constraint in a weak sense. A number of example problems involving arbitrary small and large strain constitutive models demonstrate the excellent performance of the concept pursued in this work.

Recently, a new class of fatigue crack growth models based on elastoplastic stress‐strain histories at the crack tip region and strain‐life fatigue damage models have been proposed. The fatigue crack propagation is understood as a process of continuous crack initializations, over elementary material blocks, which may be governed by strain‐life data of the plain material. The residual stresses developed at the crack tip play a central role in these models, since they are used to assess the actual crack driving force, taking into account mean stresses and loading sequential effects. The UniGrow model fits this particular class of fatigue crack propagation models. The purpose of this paper is to propose an extension of the UniGrow model to derive probabilistic fatigue crack propagation data, in particular the derivation of the P–da/dN–ΔK–R fields.

An existing deterministic fatigue crack propagation model, based on local strain‐life data is first assessed. In particular, an alternative methodology for residual stress computation is proposed, based on elastoplastic finite element analysis, in order to overcome inconsistencies found in the analytical approximate approaches often used in literature. Then, using probabilistic strain‐life fields, a probabilistic output for the fatigue crack propagation growth rates is generated. A new probabilistic fatigue field is also proposed to take mean stress effects into account, using the Smith‐Watson‐Topper (SWT) damage parameter. The proposed models are assessed using experimental data available for two materials representative from old Portuguese bridges.

A new method to generate probabilistic fatigue crack propagation rates (P–da/dN–ΔK–R fields) is proposed and verified using puddle iron from old Portuguese bridges, usually characterized by significant scatter in fatigue properties. Also, a new probabilistic fatigue field for plain material is proposed to deal with mean stress effects.

A relation between the P–ε–N and the P–da/dN–ΔK–R fields is firstly proposed in this research. Furthermore, a new P–SWT–N field is proposed to deal with mean stress effects.

The purpose of this paper is to present an efficient return mapping algorithm for elastoplastic constitutive problems of ductile metals with an exact closed form solution of the local constitutive problem in the small strain regime. A Newton Raphson iterative method is adopted for the solution of the boundary value problem.

An efficient return mapping algorithm is illustrated which is based on an elastic predictor and a plastic corrector scheme resulting in an implicit and accurate numerical integration method. Nonlinear kinematic hardening rules and linear isotropic hardening rules are used to describe the components of the hardening variables. In the adopted algorithmic approach the solution of the local constitutive equations reduces to only one straightforward nonlinear scalar equation.

The presented algorithmic scheme naturally leads to a particularly simple form of the nonlinear scalar equation which ultimately scales down to an algebraic (polynomial) equation with a single variable. The straightforwardness of the present approach allows to find the analytical solution of the algebraic equation in a closed form. Further, the consistent tangent operator is derived as associated with the proposed algorithmic scheme and it is shown that the proposed computational procedure ensures a quadratic rate of asymptotic convergence when used with a Newton Raphson iterative method for the global solution procedure.

In the present approach the solution of the algebraic nonlinear equation is found in a closed form and accordingly no iterative method is required to solve the problem of the local constitutive equations. The computational procedure ensures a quadratic rate of asymptotic convergence for the global solution procedure typical of computationally efficient solution schemes. In the paper it is shown that the proposed algorithmic scheme provides an efficient and robust computational solution procedure for elastoplasticity boundary value problems. Numerical examples and computational results are reported which illustrate the effectiveness and robustness of the adopted integration algorithm for the finite element analysis of elastoplastic structures also under elaborate loading conditions.

The purpose of this paper is to present a new effective integration method for cyclic plasticity models.

By defining an integrating factor and an augmented stress vector, the system of differential equations of the constitutive model is converted into a nonlinear dynamical system, which could be solved by an exponential map algorithm.

The numerical tests show the robustness and high efficiency of the proposed integration scheme.

The von‐Mises yield criterion in the regime of small deformation is assumed. In addition, the model obeys a general nonlinear kinematic hardening and an exponential isotropic hardening.

Integrating the constitutive equations in order to update the material state is one of the most important steps in a nonlinear finite element analysis. The accuracy of the integration method could directly influence the result of the elastoplastic analyses.

The paper deals with integrating the constitutive equations in a nonlinear finite element analysis. This subject could be interesting for the academy as well as industry. The proposed exponential‐based integration method is more efficient than the classical strategies.