Simulation and dimensional analysis of instrumented dynamic spherical indentation of ductile metals

Finite element (FE) modeling of instrumented dynamic indentation experiments in a miniature Kolsky bar is undertaken. Geometry, including an output bar with machined spherical indenter tip, and velocity history boundary conditions are extracted directly from experimental diagnostics. The test material (i.e., substrate) is polycrystalline aluminum alloy Al 6061-T6. The constitutive model used in simulations accounts for isotropic elasticity and isotropic plasticity with strain hardening, strain-rate hardening, and thermal softening under adiabatic conditions. The FE model, with representative material parameters culled from the literature, accurately reproduces the curvature of the experimental load versus depth data for three different experimental indentation velocity histories. A framework for dimensional analysis of instrumented dynamic spherical indentation is set forth, improving upon prior work. Parametric FE simulations reveal sensitivity, or lack thereof, of the predicted response to variations in the proposed independent dimensionless variables encompassing material properties. For the indenter size, maximum depth, and maximum strain rate imposed experimentally on the order of 103/s, force-depth predictions are nearly unaffected by realistic variations in mass density, melting temperature, and thermal softening parameters when the sample is initially at room temperature. Predictions are affected by elastic constants (the elastic modulus and to a lesser extent, Poisson’s ratio), initial yield strength, two strain hardening parameters, and strain rate sensitivity. Predictions are also notably affected by initial temperature, with thermal softening prominent at high enough initial temperature or much higher loading rates. Based on the dimensional analysis, static indentation and elevated temperature indentation experiments are proposed for extraction of quasi-static and thermal material properties from previously uncharacterized metals, and dynamic indentation is proposed for extraction of rate sensitivity that cannot be obtained from static tests. Rate sensitivity obtained in this way from the novel instrumented dynamic spherical indentation experiments and FE simulations produces a parameterized stress–strain response for Al 6061-T6 reasonably validated by external studies for strain rates up to the order of 103/s.