Simulating Postbuckling Behaviour and Collapse of Stiffened CFRP Panels

Advanced composite materials are well known for their outstanding potential in weight-related stiffness and strength leading to an ever increasing share in aerospace structural components out of Carbon Fibre Reinforced Plastics (CFRP). In order to fully exploit the load-carrying capacity of such structures an accurate and reliable simulation is indispensable. Local buckling is not necessarily the load bearing limit for stiffened panels or shells; their full potential can be tapped only by utilizing the postbuckling region. That, however, requires fast tools which are capable of simulating the structural behaviour beyond bifurcation points including material degradation up to collapse. The most critical structural degradation mode is skin stringer separation; delamination, especially within the stringer, is a critical material degradation. A reliable prediction of collapse requires knowledge of degradation due to static as well as low cycle loading in the postbuckling region. Earlier projects have shown that it needs considerable experience in simulating the postbuckling behaviour. Though a great deal of knowledge about CFRP structural and material degradation is available its influence on collapse is not yet sufficiently investigated. It is the aim of the project COCOMAT (Improved MATerial exploitation at safe design of COmposite airframe structures by accurate simulation of COllapse) to develop means for and gain experience in fast and accurate simulation of the collapse load of stringer stiffened CFRP curved panels taking degradation and cyclic loading as well as geometric nonlinearity into account. COCOMAT is a Specific Targeted Research Project supported by the EU 6th Framework Programme; it started 2004 and runs for 4 years. Main deliverables are: • test results for buckling and collapse of undamaged and pre-damaged stiffened CFRP panels under static and cyclic loading, • improved material properties and degradation models, computational tools for design and certification of stiffened fibre composite panels which take postbuckling behaviour, degradation and collapse into account, • and finally design guidelines and industrial validation. The work will lead to an extended experimental data base, relevant degradation models and improved simulation tools for certification as well as for design. These results should allow setting up a future design scenario which exploits the existing reserves in primary fibre composite structures. The paper starts out from results provided by the forerunners of COCOMAT, describes the main objectives of the project, gives a general status of the progress reached so far and presents first results

Postbuckling behavior of graphite-epoxy panels

Structurally efficient fuselage panels are often designed to allow buckling to occur at applied loads below ultimate. Interest in applying graphite-epoxy materials to fuselage primary structure led to several studies of the post-buckling behavior of graphite-epoxy structural components. Studies of the postbuckling behavior of flat and curved, unstiffened and stiffened graphite-epoxy panels loaded in compression and shear were summarized. The response and failure characteristics of specimens studied experimentally were described, and analytical and experimental results were compared. The specimens tested in the studies described were fabricated from commercially available 0.005-inch-thick unidirectional graphite-fiber tapes preimpregnated with 350 F cure thermosetting epoxy resins

Design and Analysis of Composite Panels

European aircraft industry demands for reduced development and operating costs, by 20% and 50% in the short and long term, respectively. Contributions to this aim are provided by the completed project POSICOSS (5thFP) and the running follow-up project COCOMAT (6thFP), both supported by the European Commission. As an important contribution to cost reduction a decrease in structural weight can be reached by exploiting considerable reserves in primary fibre composite fuselage structures through an accurate and reliable simulation of postbuckling up to collapse. The POSICOSS team developed fast procedures for postbuckling analysis of stiffened fibre composite panels, created comprehensive experimental data bases and derived design guidelines. COCOMAT builds up on the POSICOSS results and considers in addition the simulation of collapse by taking degradation into account. The results comprise an extended experimental data base, degradation models, improved certification and design tools as well as design guidelines. The projects POSICOSS and COCOMAT develop improved tools which are validated by experimental results obtained during the projects. Because the new tools must consider a wide range of different aspects a lot of different structures had to be tested. These structures were designed under different design objectives. For the design process the consortium applied already available simulation tools and brought in their own design experience. This paper deals with the design process within both projects and the analysis procedure applied within this task. It focuses on the experience of DLR on the design and analysis of stringer stiffened CFRP panels gained in the frame of these projects

The use of damage as a design parameter for postbuckling composite aerospace structures

Advanced fibre-reinforced polymer composites have seen a rapid increase in use in aircraft structures in recent years due their high specific strength and stiffness, amongst other properties. The use of postbuckling design, where lightweight structures are designed to operate safely at loads in excess of buckling loads, has been applied to metals for decades to design highly efficient structures. However, to date, the application of postbuckling design in composite structures has been limited, as today’s analysis tools are not capable of representing the damage mechanisms that lead to structural collapse of composites in compression. The currently running four-year European Commission Project COCOMAT [1] is addressing this issue, and aims to exploit the large strength reserves of composite aerospace structures through a more accurate prediction of collapse. A methodology has been developed to analyse the collapse of composite structures that is focused on capturing the critical damage mechanisms. One aspect of the methodology is a global-local analysis technique that uses a strength criterion to predict the initiation of interlaminar damage in intact structures. Another aspect of the approach was developed for representing the growth of a pre-existing interlaminar damage region, and is based on applying multi-point constraints in the skin-stiffener interface that are controlled using fracture mechanics calculations. A separate degradation model was also included to model the in-plane ply damage mechanisms of fibre fracture, matrix cracking and fibre-matrix shear that uses a progressive failure approach. The complete analysis methodology was implemented in MSC.Marc v2005r3 using several user subroutines, and has been validated with a range of experimental tests, including fracture mechanics coupons [2], single-stiffener specimens [3] and multi-stiffener curved panels [4]. The developed methodology was used to design and analyse fuselage-representative composite panels in various pre-damaged configurations. Two panel designs were investigated, D1 and D2, which both consisted of a curved skin adhesively bonded to blade-shaped stiffeners. For the D1 panel, the pre-damage applied was a full-width skin-stiffener debond created using a Teflon insert in the adhesive layer, whilst the D2 panel was investigated with Barely Visible Impact Damage (BVID). For both panels, parametric studies were conducted using the developed methodology in order to recommend a damaged configuration suitable for experimental testing. For the D1 panel, a 100 mm length debond was selected, and the location of the damage was investigated, whilst for the D2 panel both the location and the representation of damage was varied. Based on these parametric studies, two pre-damaged configurations of the D1 panel and one pre-damaged D2 configuration were selected for experimental testing. The selected pre-damaged configurations were manufactured by Aernnova Engineering Solutions and manufactured at the Institute of Composite Structures and Adaptive Systems at the German Aerospace Center (DLR) as part of the COCOMAT project. Following manufacture, panel quality was inspected with ultrasonic and thermographic scanning and panel imperfection data was measured using the three-dimensional (3D) optical measurement system ATOS. During the test, measurements were taken using displacement transducers, strain gauges, the 3D optical measuring system ARAMIS, and optical lock-in thermography. Under compression, the panels developed a range of buckling mode shapes, and the progression of damage was monitored leading to structural collapse. In comparison with the experimental results, the analysis methodology was shown to give accurate predictions of the load-carrying behaviour, damage development and collapse load of both panels. The results demonstrated the capability of the developed tool to capture the critical damage mechanisms leading to collapse in composite structures. The advanced analysis methodology also allowed for damage to be used as a design parameter in postbuckling structures, either in the comparative analysis context of a design procedure, to assess the damage tolerance of a design, or as pre- and post-test simulations of intact and pre-damaged structures. More broadly, the results demonstrated the potential of postbuckling composite structures, and the large strength reserve available in the postbuckling region. The success of the developed analysis methodology and the potential of postbuckling composite structures have application for the next generation of lightweight aerospace structures

Quasi-buckling of micromachined beams

Buckling of structures with imperfections, quasi-buckling (QB), is studied. At the bifurcation load, these structures show a smooth transition into one of the stable postbuckling equilibrium states, instead of the traditional sudden change in deflection characteristics. QB structures can show the classical snap-through buckling behaviour, i.e., a sudden change of postbuckling equilibrium state. The QB is described with a generalized temperature, Tg, representing the compression of the structure. Imperfections and distributed deflection loads are represented by a generalized pressure, pg. Experiments on micromachined beams, exposed to heating (Tg) and to a Lorentz force (pg), verify that the QB phenomena can efficiently transfer a longitudinal stress into a transversal deflection, with a scale-factor depending on both Tg and pg

Static and Dynamic Thermomechanical Buckling Loads of Functionally Graded Plates.

In the paper the buckling phenomenon for static and dynamic loading (pulse of finite duration) of FGM plates subjected to simultaneous action of one directional compression and thermal field is presented. Thin, rectangular plates simply supported along all edges are considered. The investigations are conducted for different values of volume fraction exponent and uniform temperature rise in conjunction with mechanical dynamic pulse loading of finite duration

Probabilistic Approach for better Buckling Knock-down Factors of CFRP Cylindrical Shells - Tests and Analyses

The industry in the fields of civil and mechanical engineering, and in particular of aerospace demands for significantly reduced development and operating costs. Reduction of structural weight at safe design is one avenue to achieve this objective. The running ESA (European Space Agency) study Probabilistic Aspects of Buckling Knock Down Factors – Tests and Analyses contributes to this goal by striving for an improved buckling knock-down factor (the ratio of buckling loads of imperfect and perfect structures) for unstiffened CFRP (carbon fiber reinforce plastics) cylindrical shells, and by validation of the linear and non-linear buckling simulations based on test results. DLR is acting as study contractor. The paper presents an overview about the DLR buckling tests, the measurement setup and the buckling simulations which are done so far, and gives an outlook to the results which are expected until the end of the running project

Buckling and postbuckling behavior of square compression-loaded graphite-epoxy plates with circular cutouts

An experimental study of the postbuckling behavior of square compression-loaded graphite-epoxy plates and isotropic plates with a central circular cutout is presented. Results are presented for unidirectional (0 sub 10)s and (90 sub 10)s plates, (0/90 sub 5)s plates, and for aluminum plates. Results are also presented for (+ or - O sub 6)s angle-ply plates for values of O = 30, 46, and 60 degrees. The experimental results indicate that the change in axial stiffness of a plate at buckling is strongly dependent upon cutout size and plate orthotropy. The presence of a cutout gives rise to an internal load distribution that changes, sometimes dramtically, as a function of cutout size coupled with the plate orthotropy. In the buckled state, the role of orthotropy becomes more significant since bending in addition to membrane orthotropy is present. Most of the plates with cutouts exhibited less postbuckling stiffness than the corresponding plate without a cutout, and the postbuckling stiffness decreased with increasing cutout size. However, some of the highly orthotropic plates with cutouts exhibited more postbuckling stiffness than the corresponding plate without a cutout

Local Buckling of Thin-Walled Column of Square Cross-Section Made of In-Plane Coupled Laminate.

The non–symmetric, general laminate exhibits different types of coupling between the extension, shearing, bending and twisting. For practical reasons, the in–plane coupled laminate is a particularly interesting. In this case, the coupling between shearing andextension takes place. Details calculations were performed for a short columns of square cross-section made of in–plane coupled and fully uncoupled laminate under uniform compression. Finite element method (FEM) and analytical–numerical method (ANM) were performed. In FEM analyses, the eigenbuckling problem has been solved using the Lanczos method, whereas the nonlinear buckling analysis were performed using the Newton– Raphson method and the Ritz method. In ANM analyses, the Koiter’s asymptotic theory is applied. The relationship between forces/moments and deformations/curvature were described using classical lamination theory (CLT). The coupling between in–plane shearing and extension has a significant influence on the behavior of thin–walled structures under compression