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Procedia Structural Integrity 60 (2024) 123–135 Third International Conference on Structural Integrity 2023 (ICONS2023) Calibration of tensile tests in drop-weight impact machine and implementation in simulation of Charpy impact tests Vaibhav Gangwar a* ,S.K Acharyya b ,A. Banerjee c www.elsevier.com / locate / procedia Third International Conference on Structural Integrity 2023 (ICONS2023) Calibration of tensile tests in drop-weight impact machine and implementation in simulation of Charpy impact tests Vaibhav Gangwar a* ,S.K Acharyya b ,A. Banerjee c www.elsevier.com / locate / procedia Third International Conference on Structural Integrity 2023 (ICONS2023) Calibration of tensile tests in drop-weight impact machine and implementation in simulation of Charpy impact tests Vaibhav Gangwar a* ,S.K Acharyya b ,A. Banerjee c © 2024 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of the ICONS 2023 Organizers © 2024 The Authors. Published by ElsevierB.V. This is an open access article under the CCBY-NC-NDlicense(http: // creativecommons.org / licenses / by-nc-nd / 4.0 / ) Peer-review under responsibility of the ICONS 2023 Organizers. Keywords: Calibration; high strain rate; tensile properties; drop-weight impact machine; strain gauge 1. Introduction Characterization of armor steel from intermediate to high strain rate is necessary because it has to undergo large plastic deformation during its service. The strain rate hardening of armor steel offers significant advantage in energy absorption during ballistic impact or crash event. Therefore, rigorous testing of the material is required for efficient design application, but it is of great challenge especially at high strain rates. According to a survey report presented by (P. K.C. Wood et al. 2007a), it is typically 50 times more expensive to produce high strain rate tensile data in accordance with Euronorms (Standard 2001a).The testing technology of steels at high strain rates is still under development phase. Generally, two types of test setup commonly used for high strain rate testing are servo-hydraulic and Split Hopkinson setup.The servo-hydraulic test setup will work in open loop for strain rate (>10s -1 ) Abstract Material modeling and simulation of deformation under very high loading rate in the dynamic/impact range are applied in crash resistance, ballistic impact analysis, and other time-sensitive phenomena. Servo-hydraulic UTM tensile test data from medium to higher strain rate > (500 s -1 ) is reliable but expensive and complexity in experiment. Tensile testing at very high strain rate (upto 1500 s -1 ) can be done in a drop-weight impact testing machine with a special fixture and the impactor velocity controls strain rate. In INSTRON CEAST 9350 drop weight impact testing machine tensile tests are conducted at four velocities for amour steel. A 5MHz data acquisition system (DAQ) measures strain in specimen gauge length mounted with high-elongation strain gauge. An extensometer is used to calibrate the strain gauge in a quasi-static 10 -4 s -1 tensile test. Tensile test data from impact machine is compared with stress-strain data from the INSTRON servo-hydraulic testing machine with DIC for different strain rates. Close matching in elastic modulus, yield strength, tensile strength, and elongation are observed. Material parameters of a strain rate dependent material model (modified J-C model) are extracted from drop weight impact testing machine data clubbed with other tensile test data, used in FE simulation of very high strain rate tensile tests, and validated with experimental results. Later, the same material model and material parameters are used to simulate Charpy impact tests at various velocities and compared with experimental results which also show close matching. © 2024 The Authors. Published by ElsevierB.V. This is an open access article under the CCBY-NC-NDlicense(http: // creativecommons.org / licenses / by-nc-nd / 4.0 / ) Peer-review under responsibility of the ICONS 2023 Organizers. Keywords: Calibration; high strain rate; tensile properties; drop-weight impact machine; strain gauge a Mechancial Engineering Department, Jadavpur Univerity,Kolkata, 700032,India b Mechancial Engineering Department, Jadavpur Univerity,Kolkata, 700032,India c Proof and Experimental Establishment, Chandipur, Balasore, 756025,India a Mechancial Engineering Department, Jadavpur Univerity,Kolkata, 700032,India b Mechancial Engineering Department, Jadavpur Univerity,Kolkata, 700032,India c Proof and Experimental Establishment, Chandipur, Balasore, 756025,India a Mechancial Engineering Department, Jadavpur Univerity,Kolkata, 700032,India b Mechancial Engineering Department, Jadavpur Univerity,Kolkata, 700032,India c Proof and Experimental Establishment, Chandipur, Balasore, 756025,India Abstract Material modeling and simulation of deformation under very high loading rate in the dynamic/impact range are applied in crash resistance, ballistic impact analysis, and other time-sensitive phenomena. Servo-hydraulic UTM tensile test data from medium to higher strain rate > (500 s -1 ) is reliable but expensive and complexity in experiment. Tensile testing at very high strain rate (upto 1500 s -1 ) can be done in a drop-weight impact testing machine with a special fixture and the impactor velocity controls strain rate. In INSTRON CEAST 9350 drop weight impact testing machine tensile tests are conducted at four velocities for amour steel. A 5MHz data acquisition system (DAQ) measures strain in specimen gauge length mounted with high-elongation strain gauge. An extensometer is used to calibrate the strain gauge in a quasi-static 10 -4 s -1 tensile test. Tensile test data from impact machine is compared with stress-strain data from the INSTRON servo-hydraulic testing machine with DIC for different strain rates. Close matching in elastic modulus, yield strength, tensile strength, and elongation are observed. Material parameters of a strain rate dependent material model (modified J-C model) are extracted from drop weight impact testing machine data clubbed with other tensile test data, used in FE simulation of very high strain rate tensile tests, and validated with experimental results. Later, the same material model and material parameters are used to simulate Charpy impact tests at various velocities and compared with experimental results which also show close matching. 2452-3216 © 2024 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of the ICONS 2023 Organizers 10.1016/j.prostr.2024.05.035 ∗ Corresponding author. Tel.: + 91-980-877-8009; E-mailaddress: vaibhav8009@gmail.com 2210-7843 © 2024TheAuthors.PublishedbyElsevierB.V. ThisisanopenaccessarticleundertheCCBY-NC-NDlicense(http: // creativecommons.org / licenses / by-nc-nd / 4.0 / ) Peer-reviewunderresponsibilityoftheICONS2023Organizers. 1. Introduction Characterization of armor steel from intermediate to high strain rate is necessary because it has to undergo large plastic deformation during its service. The strain rate hardening of armor steel offers significant advantage in energy absorption during ballistic impact or crash event. Therefore, rigorous testing of the material is required for efficient design application, but it is of great challenge especially at high strain rates. According to a survey report presented by (P. K.C. Wood et al. 2007a), it is typically 50 times more expensive to produce high strain rate tensile data in accordance with Euronorms (Standard 2001a).The testing technology of steels at high strain rates is still under development phase. Generally, two types of test setup commonly used for high strain rate testing are servo-hydraulic and Split Hopkinson setup.The servo-hydraulic test setup will work in open loop for strain rate (>10s -1 ) ∗ Corresponding author. Tel.: + 91-980-877-8009; E-mailaddress: vaibhav8009@gmail.com 2210-7843 © 2024TheAuthors.PublishedbyElsevierB.V. ThisisanopenaccessarticleundertheCCBY-NC-NDlicense(http: // creativecommons.org / licenses / by-nc-nd / 4.0 / ) Peer-reviewunderresponsibilityoftheICONS2023Organizers. Abstract Material modeling and simulation of deformation under very high loading rate in the dynamic/impact range are applied in crash resistance, ballistic impact analysis, and other time-sensitive phenomena. Servo-hydraulic UTM tensile test data from medium to higher strain rate > (500 s -1 ) is reliable but expensive and complexity in experiment. Tensile testing at very high strain rate (upto 1500 s -1 ) can be done in a drop-weight impact testing machine with a special fixture and the impactor velocity controls strain rate. In INSTRON CEAST 9350 drop weight impact testing machine tensile tests are conducted at four velocities for amour steel. A 5MHz data acquisition system (DAQ) measures strain in specimen gauge length mounted with high-elongation strain gauge. An extensometer is used to calibrate the strain gauge in a quasi-static 10 -4 s -1 tensile test. Tensile test data from impact machine is compared with stress-strain data from the INSTRON servo-hydraulic testing machine with DIC for different strain rates. Close matching in elastic modulus, yield strength, tensile strength, and elongation are observed. Material parameters of a strain rate dependent material model (modified J-C model) are extracted from drop weight impact testing machine data clubbed with other tensile test data, used in FE simulation of very high strain rate tensile tests, and validated with experimental results. Later, the same material model and material parameters are used to simulate Charpy impact tests at various velocities and compared with experimental results which also show close matching. © 2024 The Authors. Published by ElsevierB.V. This is an open access article under the CCBY-NC-NDlicense(http: // creativecommons.org / licenses / by-nc-nd / 4.0 / ) Peer-review under responsibility of the ICONS 2023 Organizers. Keywords: Calibration; high strain rate; tensile properties; drop-weight impact machine; strain gauge 1. Introduction Characterization of armor steel from intermediate to high strain rate is necessary because it has to undergo large plastic deformation during its service. The strain rate hardening of armor steel offers significant advantage in energy absorption during ballistic impact or crash event. Therefore, rigorous testing of the material is required for efficient design application, but it is of great challenge especially at high strain rates. According to a survey report presented by (P. K.C. Wood et al. 2007a), it is typically 50 times more expensive to produce high strain rate tensile data in accordance with Euronorms (Standard 2001a).The testing technology of steels at high strain rates is still under development phase. Generally, two types of test setup commonly used for high strain rate testing are servo-hydraulic and Split Hopkinson setup.The servo-hydraulic test setup will work in open loop for strain rate (>10s -1 ) ∗ Corresponding author. Tel.: + 91-980-877-8009; E-mailaddress: vaibhav8009@gmail.com 2210-7843 © 2024TheAuthors.PublishedbyElsevierB.V. ThisisanopenaccessarticleundertheCCBY-NC-NDlicense(http: // creativecommons.org / licenses / by-nc-nd / 4.0 / ) Peer-reviewunderresponsibilityoftheICONS2023Organizers.