Virtual Element based formulations for computational materials micro-mechanics and homogenization

In this thesis, a computational framework for microstructural modelling of transverse behaviour of heterogeneous materials is presented. The context of this research is part of the broad and active field of Computational Micromechanics, which has emerged as an effective tool both to understand the influence of complex microstructure on the macro-mechanical response of engineering materials and to tailor-design innovative materials for specific applications through a proper modification of their microstructure. While the classical continuum approximation does not account for microstructural details within the material, computational micromechanics allows detailed modelling of a heterogeneous material's internal structural arrangement by treating each constituent as a continuum. Such an approach requires modelling a certain material microstructure by considering most of the microstructure's morphological features. The most common numerical technique used in computational micromechanics analysis is the Finite Element Method (FEM). Its use has been driven by the development of mesh generation programs, which lead to the quasi-automatic discretisation of the artificial microstructure domain and the possibility of implementing appropriate constitutive equations for the different phases and their interfaces. In FEM's applications to computational micromechanics, the phase arrangements are discretised using continuum elements. The mesh is created so that element boundaries and, wherever required, special interface elements are located at all interfaces between material's constituents. This approach can be effective in modelling many microstructures, and it is readily available in commercial codes. However, the need to accurately resolve the kinematic and stress fields related to complex material behaviours may lead to very large models that may need prohibitive processing time despite the increasing modern computers' performance. When rather complex microstructure's morphologies are considered, the quasi-automatic discretisation process stated before might fail to generate high-quality meshes. Time-consuming mesh regularisation techniques, both automatic and operator-driven, may be needed to obtain accurate numeric results. Indeed, the preparation of high-quality meshes is today one of the steps requiring more attention, and time, from the analyst. In this respect, the development of computational techniques to deal with complex and evolving geometries and meshes with accuracy, effectiveness, and robustness attracts relevant interest. The computational framework presented in this thesis is based on the Virtual Element Method (VEM), a recently developed numerical technique that has proven to provide robust numerical results even with highly-distorted mesh. These peculiar features have been exploited to analyse two-dimensional representations of heterogeneous materials' microstructures. Ad-hoc polygonal multi-domain meshing strategies have been developed and tested to exploit the discretisation freedom that VEM allows. To further simplify the preprocessing stage of the analysis and reduce the total computational cost, a novel hybrid formulation for analysing multi-domain problems has been developed by combining the Virtual Element Method with the well-known Boundary Element Method (BEM). The hybrid approach has been used to study both composite material's transverse behaviour in the presence of inclusions with complex geometries and damage and crack propagation in the matrix phase. Numerical results are presented that demonstrate the potential of the developed framework

Fibre-reinforced additive manufacturing: from design guidelines to advanced lattice structures

In pursuit of achieving ultimate lightweight designs with additive manufacturing (AM), engineers across industries are increasingly gravitating towards composites and architected cellular solids; more precisely, fibre-reinforced polymers and functionally graded lattices (FGLs). Control over material anisotropy and the cell topology in design for AM (DfAM) offer immense scope for customising a part’s properties and for the efficient use of material. This research expands the knowledge on the design with fibre-reinforced AM (FRAM) and the elastic-plastic performance of FGLs. Novel toolpath strategies, design guidelines and assessment criteria for FRAM were developed. For this purpose, an open-source solution was proposed, successfully overcoming the limitations of commercial printers. The effect of infill patterns on structural performance, economy, and manufacturability was examined. It was demonstrated how print paths informed by stress trajectories and key geometric features can outperform conventional patterns, laying the groundwork for more sophisticated process planning. A compilation of the first comprehensive database on fibre-reinforced FGLs provided insights into the effect of grading on the elastic performance and energy absorption capability, subject to strut-and surface-based lattices, build direction and fibre volume fraction. It was elucidated how grading the unit cell density within a lattice offers the possibility of tailoring the stiffness and achieving higher energy absorption than ungraded lattices. Vice versa, grading the unit cell size of lattices yielded no effect on the performance and is thus exclusively governed by the density. These findings help exploit the lightweight potential of FGLs through better informed DfAM. A new and efficient methodology for predicting the elastic-plastic characteristics of FGLs under large strain deformation, assuming homogenised material properties, was presented. A phenomenological constitutive model that was calibrated based upon interpolated material data of uniform density lattices facilitated a computationally inexpensive simulation approach and thus helps streamline the design workflow with architected lattices.Open Acces

Failure and damage progression of 3D woven composite structures subjected to out-of-plane loading

Three-dimensionally woven composites are a relatively new class of material that offer improved out-of-plane performance by including through-the-thickness mechanical reinforcement compared to traditional laminated composite structures. The mechanical properties are highly dependent upon the weave architecture as this dictates the nature of the through the thickness reinforcement and its effect in improving out-of-plane shear strength. A comparison of two testing methods, Short Beam Strength, and Five Point Bending was conducted over a range of span to thickness ratios with the latter found to be more consistent at producing shear failure over a greater range of span to thickness ratios, although evidence of matrix crushing was present in both, and flexural failure in the Short Beam Strength test. Two weave architectures, the orthogonal and angle weave were subjected to the Five Point Bending test and the failure and damage progression behaviour of both weave architectures were characterised using Digital Image Correlation analysis to measure the edge strain through the thickness of the specimens. This testing showed the angle weave architecture had in general a higher failure strength, and more gradual failure due to longer debonding cracks. The orthogonal weave architecture showed a characteristic post-failure response indicative of crack bridging with discrete load recovery and load drop phases. A numerical model developed from previous work builds on the mosaic modelling method and was modified to include cohesive elements in order to simulate interface debonding via the maximum stress criterion. The simulations are consistently 15 20% greater in failure loads, and 8 - 12% greater in failure shear stresses than those found from the averaged experimental results over the range of tested span to thickness ratios. Post failure response was not modelled. The work presented in this thesis is another step towards gaining a thorough understanding of the mechanical properties of 3D woven composite structures, focussing in particular on out of plane shear strength. The modified mosaic modelling method used showed it is effective at modelling the out of plane testing of orthogonal 3D woven composite structures, and offer the potential to predict the failure of larger composite structures of the same construction and 3D woven architecture although developments are still needed in modelling the post failure response

Aeropropulsion 1987

Papers from the Aeropropulsion '87 Conference, held at the NASA Lewis Research Center (LeRC), are presented. Unclassified presentations by LeRC and NASA Headquarters senior management and many LeRC technical authors covered the philosophy and major directions of the LeRC aeropropulsion program, and presented a broad spectrum of recent research results in materials, structures, internal fluid mechanics, instrumentation and controls, and both subsonic and high-speed propulsion technology

Proceedings of the 2018 Canadian Society for Mechanical Engineering (CSME) International Congress

Published proceedings of the 2018 Canadian Society for Mechanical Engineering (CSME) International Congress, hosted by York University, 27-30 May 2018

Optimisation of high-speed automated layup of thermoset carbon-fibre preimpregnates

EThOS - Electronic Theses Online ServiceGBUnited Kingdo

Advanced Applications of Rapid Prototyping Technology in Modern Engineering

Rapid prototyping (RP) technology has been widely known and appreciated due to its flexible and customized manufacturing capabilities. The widely studied RP techniques include stereolithography apparatus (SLA), selective laser sintering (SLS), three-dimensional printing (3DP), fused deposition modeling (FDM), 3D plotting, solid ground curing (SGC), multiphase jet solidification (MJS), laminated object manufacturing (LOM). Different techniques are associated with different materials and/or processing principles and thus are devoted to specific applications. RP technology has no longer been only for prototype building rather has been extended for real industrial manufacturing solutions. Today, the RP technology has contributed to almost all engineering areas that include mechanical, materials, industrial, aerospace, electrical and most recently biomedical engineering. This book aims to present the advanced development of RP technologies in various engineering areas as the solutions to the real world engineering problems

Aeronautical Engineering: A continuing bibliography with indexes, supplement 128, November 1980

This bibliography lists 419 reports, articles, and other documents introduced into the NASA scientific and technical information system in October 1980