diff --git a/test/materials/test_finite_strain_plasticity.jl b/test/materials/test_finite_strain_plasticity.jl new file mode 100644 index 0000000..5e0b2b1 --- /dev/null +++ b/test/materials/test_finite_strain_plasticity.jl @@ -0,0 +1,328 @@ +""" +# Unit Tests: Finite Strain Plasticity (Multiplicative Decomposition) + +**What:** Comprehensive validation of finite strain J2 plasticity with F = F_e F_p decomposition + +**Why:** +- Geometrically exact plasticity for large deformations (>10% strain) +- Tests multiplicative decomposition F = F_e F_p (not additive ε = ε_e + ε_p) +- Validates plastic incompressibility det(F_p) = 1 (fundamental constraint) +- Critical for metal forming, impact, crashworthiness (extreme deformations) +- Demonstrates objective stress update (rotation-independent) + +**How:** +Test suite validates: +1. **Construction & parameters** - E, ν, σ_y, H validity, computed μ and λ +2. **State management** - FiniteStrainPlasticityState(F_p, α_bar, κ) with F_p=I default +3. **Small strain limit** - Should recover small-strain plasticity for F ≈ I + ∇u +4. **Identity deformation** - F = I gives σ = 0, F_p = I, κ = 0 +5. **Pure rotation** - Rigid body rotation (no stretch) should give σ ≈ 0 (objectivity) +6. **Uniaxial extension** - Elastic (λ=1.01) and plastic (λ=1.10) regimes +7. **Simple shear** - Validates shear response, det(F) = 1 +8. **Incremental loading** - Monotonic loading: stress and κ increase +9. **Plastic incompressibility** - det(F_p) ≈ 1 for all stretches λ ∈ [1.02, 1.20] +10. **Hardening behavior** - H > 0: higher stress, backstress α_bar ≠ 0 +11. **State persistence** - Unloading: plastic strain κ does not decrease +12. **Performance** - Type stability + +**Mathematical Background:** +- Multiplicative decomposition: F = F_e F_p (Lee decomposition) + - F: Total deformation gradient + - F_e: Elastic part (recoverable on unloading) + - F_p: Plastic part (permanent deformation) +- Plastic incompressibility: det(F_p) = 1 (volume preservation in plastic flow) +- Mandel stress: M = C_e S_e (intermediate configuration) +- Yield criterion: f = √(3/2·dev(M):dev(M)) - σ_y ≤ 0 (von Mises) +- Flow rule: Ḟ_p F_p⁻¹ = Δγ·n (exponential map integration) +- Hardening: α̇_bar = H·ε̇_p (backstress evolution in intermediate config) +- Objectivity: σ(Q·F) = Q·σ(F)·Q^T for rotation Q (frame-invariance) +- Physical constraints: det(F) > 0, det(F_e) > 0, det(F_p) = 1 + +**Expected Results:** +✅ Material constructed: E=200 GPa, ν=0.3, σ_y=250 MPa, H=0-10 GPa +✅ Perfect plasticity: H=0 valid +✅ Invalid inputs rejected: E<0, ν>0.5, σ_y<0, H<0, κ<0 +✅ Default state: F_p=I (det=1), α_bar=0, κ=0 +✅ Small strain (ε=1e-5): F_p≈I, κ=0, ||σ|| < 1 MPa +✅ Identity (F=I): σ=0 exactly +✅ Pure rotation (45° around z): ||σ|| < 1 MPa (objectivity), F_p≈I +✅ Uniaxial elastic (λ=1.01): F_p≈I, κ=0, σ_xx > 0 +✅ Uniaxial plastic (λ=1.10): ||F_p-I|| > 1e-6, κ > 0, |det(F_p)-1| < 0.001 +✅ Simple shear (γ=0.1): σ_xy ≠ 0, det(F)=1 +✅ Incremental (5 steps to λ=1.05): Monotonic stress and κ +✅ Incompressibility: |det(F_p)-1| < 0.01 for λ ∈ [1.02,1.20] +✅ Hardening: H=10 GPa → σ > σ_perfect, ||α_bar|| > 0 +✅ State persistence: Load λ=1.08 then unload λ=1.02 → κ doesn't decrease +✅ Simplified interface (without state, Δt) matches full call +✅ Type-stable: returns Tuple{SymmetricTensor{2,3}, SymmetricTensor{4,3}, FiniteStrainPlasticityState} + +**Test Coverage:** +- 14 test sets, ~70 individual assertions +- Material constants: Steel (E=200 GPa, ν=0.3, σ_y=250 MPa, H=0-10 GPa) +- Deformations: Identity, small (ε=1e-5), rotation (45°), uniaxial (λ=1.01-1.20), shear (γ=0.1) +- Validation methods: Plastic incompressibility, objectivity, state persistence, hardening comparison +- Algorithms: Multiplicative decomposition, exponential map, return mapping in intermediate config +- Edge cases: Perfect plasticity (H=0), pure rotation, incremental loading, unloading + +**Key Physics:** +- Multiplicative decomposition: Geometrically exact (not linearized) +- Plastic incompressibility: Fundamental for metals (no volume change in plastic flow) +- Objectivity: Stress independent of observer reference frame (essential for large rotations) +- Lee decomposition: Separates elastic (lattice stretch) from plastic (slip) deformations +- Intermediate configuration: Where plasticity lives (stress-free but plastically deformed) +- Exponential map: Preserves det(F_p) = 1 during integration (unlike additive schemes) +""" + +using Test +using Tensors +using LinearAlgebra + +# Load implementations +include("../src/materials/abstract_material.jl") +include("../src/materials/finite_strain_plasticity.jl") + +@testset "Finite Strain Plasticity Material" begin + + @testset "Material Construction" begin + # Valid construction + steel = FiniteStrainPlasticity(E=200e9, ν=0.3, σ_y=250e6, H=1e9) + @test steel.E == 200e9 + @test steel.ν == 0.3 + @test steel.σ_y == 250e6 + @test steel.H == 1e9 + @test steel.μ ≈ 200e9 / (2 * (1 + 0.3)) + @test steel.λ ≈ 200e9 * 0.3 / ((1 + 0.3) * (1 - 2 * 0.3)) + + # Perfect plasticity (H=0) + perfect = FiniteStrainPlasticity(E=200e9, ν=0.3, σ_y=250e6, H=0.0) + @test perfect.H == 0.0 + + # Invalid inputs + @test_throws ArgumentError FiniteStrainPlasticity(E=-200e9, ν=0.3, σ_y=250e6, H=1e9) + @test_throws ArgumentError FiniteStrainPlasticity(E=200e9, ν=0.6, σ_y=250e6, H=1e9) + @test_throws ArgumentError FiniteStrainPlasticity(E=200e9, ν=0.3, σ_y=-250e6, H=1e9) + @test_throws ArgumentError FiniteStrainPlasticity(E=200e9, ν=0.3, σ_y=250e6, H=-1e9) + end + + @testset "State Construction" begin + # Default state (identity F_p) + state0 = FiniteStrainPlasticityState() + @test state0.F_p == one(Tensor{2,3}) + @test state0.α_bar == zero(SymmetricTensor{2,3}) + @test state0.κ == 0.0 + @test det(state0.F_p) ≈ 1.0 + + # Custom state + F_p = one(Tensor{2,3}) + 0.01 * Tensor{2,3}((0.0, 0.01, 0.0, 0.0, 0.0, 0.0, 0.0, 0.0, 0.0)) + F_p = F_p / det(F_p)^(1 / 3) # Enforce det = 1 + α_bar = SymmetricTensor{2,3}((1e8, 0.0, 0.0, 0.0, 0.0, 0.0)) + state = FiniteStrainPlasticityState(F_p, α_bar, 0.01) + @test state.F_p ≈ F_p + @test state.α_bar == α_bar + @test state.κ == 0.01 + + # Invalid state (negative κ) + @test_throws ArgumentError FiniteStrainPlasticityState(F_p, α_bar, -0.01) + end + + @testset "Small Strain Limit" begin + steel = FiniteStrainPlasticity(E=200e9, ν=0.3, σ_y=250e6, H=1e9) + + # Small deformation: F ≈ I + ∇u + ε_small = 1e-5 + F_small = one(Tensor{2,3}) + ε_small * Tensor{2,3}((1.0, 0.0, 0.0, 0.0, 0.0, 0.0, 0.0, 0.0, 0.0)) + + σ, 𝔸, state = compute_stress(steel, F_small, nothing, 0.0) + + # Should remain elastic + @test state.F_p ≈ one(Tensor{2,3}) + @test state.α_bar == zero(SymmetricTensor{2,3}) + @test state.κ == 0.0 + + # Stress should be small + @test norm(σ) < 1e6 # Less than 1 MPa + end + + @testset "Identity Deformation" begin + steel = FiniteStrainPlasticity(E=200e9, ν=0.3, σ_y=250e6, H=1e9) + F_identity = one(Tensor{2,3}) + + σ, 𝔸, state = compute_stress(steel, F_identity, nothing, 0.0) + + # Zero stress for no deformation + @test norm(σ) < 1e-10 + @test state.F_p == one(Tensor{2,3}) + @test state.κ == 0.0 + end + + @testset "Pure Rotation (Elastic)" begin + steel = FiniteStrainPlasticity(E=200e9, ν=0.3, σ_y=250e6, H=1e9) + + # 45-degree rotation around z-axis (no stretching) + θ = π / 4 + c = cos(θ) + s = sin(θ) + R = Tensor{2,3}((c, s, 0.0, -s, c, 0.0, 0.0, 0.0, 1.0)) + + σ, 𝔸, state = compute_stress(steel, R, nothing, 0.0) + + # Pure rotation should give zero stress (if formulation is objective) + # Note: May not be exactly zero due to numerical precision + @test norm(σ) < 1e6 # Should be small + @test state.F_p ≈ one(Tensor{2,3}) rtol = 1e-6 + end + + @testset "Uniaxial Extension (Elastic)" begin + steel = FiniteStrainPlasticity(E=200e9, ν=0.3, σ_y=250e6, H=1e9) + + # 1% extension in x-direction + λ = 1.01 + F_ext = Tensor{2,3}((λ, 0.0, 0.0, 0.0, 1.0, 0.0, 0.0, 0.0, 1.0)) + + σ, 𝔸, state = compute_stress(steel, F_ext, nothing, 0.0) + + # Should remain elastic (small extension) + @test state.F_p ≈ one(Tensor{2,3}) rtol = 1e-6 + @test state.κ == 0.0 + + # Check that σ_xx > 0 (tension) + @test σ[1, 1] > 0.0 + end + + @testset "Uniaxial Extension (Plastic)" begin + steel = FiniteStrainPlasticity(E=200e9, ν=0.3, σ_y=250e6, H=1e9) + + # Large extension (10%) + λ = 1.10 + F_ext = Tensor{2,3}((λ, 0.0, 0.0, 0.0, 1.0, 0.0, 0.0, 0.0, 1.0)) + + σ, 𝔸, state = compute_stress(steel, F_ext, nothing, 0.0) + + # Should have plastic deformation + @test norm(state.F_p - one(Tensor{2,3})) > 1e-6 + @test state.κ > 0.0 + + # Plastic incompressibility: det(F_p) ≈ 1 + @test abs(det(state.F_p) - 1.0) < 1e-3 + end + + @testset "Simple Shear" begin + steel = FiniteStrainPlasticity(E=200e9, ν=0.3, σ_y=250e6, H=1e9) + + # Shear deformation: γ = 0.1 + γ = 0.1 + F_shear = Tensor{2,3}((1.0, γ, 0.0, 0.0, 1.0, 0.0, 0.0, 0.0, 1.0)) + + σ, 𝔸, state = compute_stress(steel, F_shear, nothing, 0.0) + + # Check shear stress exists + @test abs(σ[1, 2]) > 0.0 + + # det(F) should be 1 for simple shear + @test abs(det(F_shear) - 1.0) < 1e-10 + end + + @testset "Incremental Loading" begin + steel = FiniteStrainPlasticity(E=200e9, ν=0.3, σ_y=250e6, H=1e9) + + # Load in increments + n_steps = 5 + λ_max = 1.05 + + state = FiniteStrainPlasticityState() + stresses = Float64[] + plastic_strains = Float64[] + + for i in 1:n_steps + λ = 1.0 + (λ_max - 1.0) * i / n_steps + F = Tensor{2,3}((λ, 0.0, 0.0, 0.0, 1.0, 0.0, 0.0, 0.0, 1.0)) + σ, 𝔸, state = compute_stress(steel, F, state, 0.0) + + push!(stresses, σ[1, 1]) + push!(plastic_strains, state.κ) + end + + # Stress should increase (with hardening) + @test all(diff(stresses) .≥ -1e-6) # Allow small numerical errors + + # Plastic strain should increase monotonically + @test all(diff(plastic_strains) .≥ 0.0) + end + + @testset "Plastic Incompressibility" begin + steel = FiniteStrainPlasticity(E=200e9, ν=0.3, σ_y=250e6, H=1e9) + + # Various deformation levels + stretches = [1.02, 1.05, 1.10, 1.15, 1.20] + + for λ in stretches + F = Tensor{2,3}((λ, 0.0, 0.0, 0.0, 1.0, 0.0, 0.0, 0.0, 1.0)) + σ, 𝔸, state = compute_stress(steel, F, nothing, 0.0) + + # Check plastic incompressibility + det_Fp = det(state.F_p) + @test abs(det_Fp - 1.0) < 0.01 # Within 1% (relaxed due to exponential map approximation) + end + end + + @testset "Hardening Behavior" begin + steel_hard = FiniteStrainPlasticity(E=200e9, ν=0.3, σ_y=250e6, H=10e9) + steel_perf = FiniteStrainPlasticity(E=200e9, ν=0.3, σ_y=250e6, H=0.0) + + F_test = Tensor{2,3}((1.08, 0.0, 0.0, 0.0, 1.0, 0.0, 0.0, 0.0, 1.0)) + + σ_hard, _, state_hard = compute_stress(steel_hard, F_test, nothing, 0.0) + σ_perf, _, state_perf = compute_stress(steel_perf, F_test, nothing, 0.0) + + # Hardening material should have higher stress + @test σ_hard[1, 1] > σ_perf[1, 1] + + # Hardening material should have backstress + @test norm(state_hard.α_bar) > 0.0 + @test norm(state_perf.α_bar) == 0.0 + end + + @testset "State Persistence" begin + steel = FiniteStrainPlasticity(E=200e9, ν=0.3, σ_y=250e6, H=1e9) + + # First load + F1 = Tensor{2,3}((1.08, 0.0, 0.0, 0.0, 1.0, 0.0, 0.0, 0.0, 1.0)) + σ1, _, state1 = compute_stress(steel, F1, nothing, 0.0) + + # Unload to smaller deformation + F2 = Tensor{2,3}((1.02, 0.0, 0.0, 0.0, 1.0, 0.0, 0.0, 0.0, 1.0)) + σ2, _, state2 = compute_stress(steel, F2, state1, 0.0) + + # Plastic strain should not decrease + @test state2.κ ≥ state1.κ + + # F_p should not go back to identity + @test norm(state2.F_p - one(Tensor{2,3})) > 1e-6 + end + + @testset "Simplified Interface" begin + steel = FiniteStrainPlasticity(E=200e9, ν=0.3, σ_y=250e6, H=1e9) + F = Tensor{2,3}((1.05, 0.0, 0.0, 0.0, 1.0, 0.0, 0.0, 0.0, 1.0)) + + # Test with and without explicit state/Δt + σ1, 𝔸1, state1 = compute_stress(steel, F) + σ2, 𝔸2, state2 = compute_stress(steel, F, nothing, 0.0) + + @test σ1 ≈ σ2 + @test state1.κ ≈ state2.κ + end + + @testset "Type Stability" begin + steel = FiniteStrainPlasticity(E=200e9, ν=0.3, σ_y=250e6, H=1e9) + F = Tensor{2,3}((1.05, 0.0, 0.0, 0.0, 1.0, 0.0, 0.0, 0.0, 1.0)) + state = FiniteStrainPlasticityState() + + # Infer return types + result = @inferred compute_stress(steel, F, state, 0.0) + + @test result isa Tuple{SymmetricTensor{2,3,Float64}, + SymmetricTensor{4,3,Float64}, + FiniteStrainPlasticityState} + end + +end