Buckling strength improvements for Fibre Metal Laminates using thin-ply tailoring

The buckling response and load carrying capacity of thin-walled open cross-section profiles made of Fibre Metal Laminates, subjected to static axial compression loading are considered. These include thin-walled Z-shape and channel cross-section profiles adopting a 3/2 FML lay-up design, made of 3 aluminium layers. The objective of the investigation is the comparison of standard thickness Fibre Reinforced Plastic layers versus thin-ply material technology. Whilst thin ply designs differ only by the layer thickness, they offer an exponential increase in stacking sequence design freedoms, allowing detrimental coupling effects to be eliminated. The benefit of different hybrid materials are also considered. The comparisons involve semi-analytical and finite element methods, which are validated against experimental investigations

Investigation of asymmetrical fiber metal hybrids used as load introduction element for thin-walled CFRP structures

Due to the industrial success of fiber reinforced plastic (FRP) light-weight components, the demand for joining methods suitable for FRP increases as well. Conventional joining elements like rivets and screws or simple clamping are designed for an application in conventional isotropic materials such as steel or aluminum. Therefore, by design these joining elements do not consider characteristic FRP properties such as the orthotropic (fiber) or the setting behavior of matrix materials that are subjected to a constant load. Thus, without any FRP specific adjustments, conventional joining elements will, in most cases, lead to poor results and an inferior joint. Hence, this investigation presents the concept of a layered local metal-hybrid area that can be used as a load introduction element, the "Multilayer-Insert". The design aspects of the hybrid area are discussed for several stacking options. Furthermore, the sensitivity to geometrical design variables and asymmetrical stackings are investigated by a simplified two-dimensional finite element model. The deduced parameter relations are discussed in the context of an application in an automated fiber placement process in order to formulate recommendations for the geometrical parameters

Experimental and numerical study of the energy absorption capacity of pultruded composite tubes

A numerical and experimental investigation was carried out in order to evaluate the response of composite tubes, made of poly-vinylester or polyester matrix reinforced unidirectionally with glass fibers, under quasistatic loading. The influence of triggering in failure and energy absorption was investigated. Also a series of finite element models was created using LS-DYNA3D and compared with experimental results. The correlation between simulations and experiments was relatively satisfactory and from the results of the study the energy absorbing suitability of each tube was evaluated. Results would provide more data that are needed for designing effective energy absorption mechanisms subjected under high speed loads

Study of structural joints with composite materials to enhance the mechanical response of bus superstructures

Steel structures have an ubiquitous presence in several industries due to their availability and low price. Bus super-structures are typically built using structural steel hollow shapes and serve a major role during crashes and rollovers, as they protect the passengers by absorbing the kinetic energy of impacts and dissipating it as plastic deformations. In recent years, composite materials have gained protagonism in numerous applications due to their high specific strength and stiffness. However, costs and manufacturing complexity have made all-composite automotive structures economically unfeasible. Thus, the current tendency is the use of multimaterial structures: using composites only in the zones where they are needed, while keeping an inexpensive material, like steel, elsewhere. Hollow structural shapes, used in bus structures, are susceptible to bending collapse failure during rollover and crashes, which must be precisely predicted and calculated. Existing theoretical models for this failure mechanism have certain limitations to account for larger thickness, plastic hardening, and composite reinforcements. The present work aims to address these limitations through the development of new theoretical models for the so-called medium-thin-walled hollow shapes, as well as for reinforced CFRP-Steel hollow shapes. Both materials are joined using structural adhesives due to their ease-of-use and relatively low price. Experimental test results have shown the validity and accuracy of the proposed models. These proposed models are then implemented in a concept model of a bus structure to address its crashworthiness and the effectiveness of the reinforced shapes

A new mixed model based on the enhanced-Refined Zigzag Theory for the analysis of thick multilayered composite plates

The Refined Zigzag Theory (RZT) has been widely used in the numerical analysis of multilayered and sandwich plates in the last decay. It has been demonstrated its high accuracy in predicting global quantities, such as maximum displacement, frequencies and buckling loads, and local quantities such as through-the-thickness distribution of displacements and in-plane stresses [1,2]. Moreover, the C0 continuity conditions make this theory appealing to finite element formulations [3]. The standard RZT, due to the derivation of the zigzag functions, cannot be used to investigate the structural behaviour of angle-ply laminated plates. This drawback has been recently solved by introducing a new set of generalized zigzag functions that allow the coupling effect between the local contribution of the zigzag displacements [4]. The newly developed theory has been named enhanced Refined Zigzag Theory (en- RZT) and has been demonstrated to be very accurate in the prediction of displacements, frequencies, buckling loads and stresses. The predictive capabilities of standard RZT for transverse shear stress distributions can be improved using the Reissner’s Mixed Variational Theorem (RMVT). In the mixed RZT, named RZT(m) [5], the assumed transverse shear stresses are derived from the integration of local three-dimensional equilibrium equations. Following the variational statement described by Auricchio and Sacco [6], the purpose of this work is to implement a mixed variational formulation for the en-RZT, in order to improve the accuracy of the predicted transverse stress distributions. The assumed kinematic field is cubic for the in-plane displacements and parabolic for the transverse one. Using an appropriate procedure enforcing the transverse shear stresses null on both the top and bottom surface, a new set of enhanced piecewise cubic zigzag functions are obtained. The transverse normal stress is assumed as a smeared cubic function along the laminate thickness. The assumed transverse shear stresses profile is derived from the integration of local three-dimensional equilibrium equations. The variational functional is the sum of three contributions: (1) one related to the membrane-bending deformation with a full displacement formulation, (2) the Hellinger-Reissner functional for the transverse normal and shear terms and (3) a penalty functional adopted to enforce the compatibility between the strains coming from the displacement field and new “strain” independent variables. The entire formulation is developed and the governing equations are derived for cases with existing analytical solutions. Finally, to assess the proposed model’s predictive capabilities, results are compared with an exact three-dimensional solution, when available, or high-fidelity finite elements 3D models. References: [1] Tessler A, Di Sciuva M, Gherlone M. Refined Zigzag Theory for Laminated Composite and Sandwich Plates. NASA/TP- 2009-215561 2009:1–53. [2] Iurlaro L, Gherlone M, Di Sciuva M, Tessler A. Assessment of the Refined Zigzag Theory for bending, vibration, and buckling of sandwich plates: a comparative study of different theories. Composite Structures 2013;106:777–92. https://doi.org/10.1016/j.compstruct.2013.07.019. [3] Di Sciuva M, Gherlone M, Iurlaro L, Tessler A. A class of higher-order C0 composite and sandwich beam elements based on the Refined Zigzag Theory. Composite Structures 2015;132:784–803. https://doi.org/10.1016/j.compstruct.2015.06.071. [4] Sorrenti M, Di Sciuva M. An enhancement of the warping shear functions of Refined Zigzag Theory. Journal of Applied Mechanics 2021;88:7. https://doi.org/10.1115/1.4050908. [5] Iurlaro L, Gherlone M, Di Sciuva M, Tessler A. A Multi-scale Refined Zigzag Theory for Multilayered Composite and Sandwich Plates with Improved Transverse Shear Stresses, Ibiza, Spain: 2013. [6] Auricchio F, Sacco E. Refined First-Order Shear Deformation Theory Models for Composite Laminates. J Appl Mech 2003;70:381–90. https://doi.org/10.1115/1.1572901

Experimental and numerical study on vibration and buckling characteristics of laminated composite plates

Composite materials are being increasingly used in automotive, civil, marine, and especially weight sensitive aerospace application, primarily because of its specific strength and stiffness. The present research is mostly experimental study based on vibration measurement and buckling behavior of industry driven woven fiber composite panels. The effects of different geometry, boundary conditions, aspect ratio and type of fiber and hygrothermal conditions on the natural frequencies of vibration and buckling of woven fiber composite panels are studied in this investigation. Experiments have also been conducted to study the vibration and buckling characteristics of carbon/glass hybrid plates for different lamination sequence and percentage of carbon and glass fiber. The finite element package, ANSYS 13.0 was used to obtain numerical results and validate the experimental results obtained. The free vibration characteristics are studied with FFT analyzer. The critical buckling load is determined using INSTRON 1195. From the results obtained it was observed that, the frequencies of vibration as well as critical buckling load increased with increase in thickness. As the conditioning temperature deviates from the manufacturing temperature, the natural frequencies decrease gradually. The increase in moisture concentration of the laminate results in decrease in the modal frequencies. The studies on hybrid plates show that they possess the advantages of both their constituent fibres and have properties intermediate to the properties of individual fibres. The effect of percentage composition and sequence of lamination of the fibres on vibrational and buckling characteristics of the composite plates were observed. It was observed that the failure due to tensile load in hybrids is governed by delamination between layers. The buckling results show that stiffer materials on outermost layer give maximum buckling strength compared to those with carbon fibres in inner layers

Design of Eco-Efficient Body Parts for Electric Vehicles Considering Life Cycle Environmental Information

The reduction of greenhouse gas (GHG) emissions over the entire life cycle of vehicles has become part of the strategic objectives in automotive industry. In this regard, the design of future body parts should be carried out based on information of life cycle GHG emissions. The substitution of steel towards lightweight materials is a major trend, with the industry undergoing a fundamental shift towards the introduction of electric vehicles (EV). The present research aims to support the conceptual design of body parts with a combined perspective on mechanical performance and life cycle GHG emissions. Particular attention is paid to the fact that the GHG impact of EV in the use phase depends on vehicle-specific factors that may not be specified at the conceptual design stage of components, such as the market-specific electricity mix used for vehicle charging. A methodology is proposed that combines a simplified numerical design of concept alternatives and an analytic approach estimating life cycle GHG emissions. It is applied to a case study in body part design based on a set of principal geometries and load cases, a range of materials (aluminum, glass and carbon fiber reinforced plastics (GFRP, CFRP) as substitution to a steel reference) and different use stage scenarios of EV. A new engineering chart was developed, which helps design engineers to compare life cycle GHG emissions of lightweight material concepts to the reference. For body shells, the replacement of the steel reference with aluminum or GFRP shows reduced lifecycle GHG emissions for most use phase scenarios. This holds as well for structural parts being designed on torsional stiffness. For structural parts designed on tension/compression or bending stiffness CFRP designs show lowest lifecycle GHG emissions. In all cases, a high share of renewable electricity mix and a short lifetime pose the steel reference in favor. It is argued that a further elaboration of the approach could substantially increase transparency between design choices and life cycle GHG emissions

Material choice to optimise the performance index of isogrid structures

Three key qualities should define the structures used in the aviation industry: they should be light, rigid, and strong. These goals can be met by selecting lightweight, high-performance materials like titanium alloy or composites, but careful structural design is also crucial to improve mechanical performance. The structures known as isogrids, which consist of a skin reinforced by a lattice frame, offer an effective way to meet the aforementioned specifications. The structural performances of isogrid-stiffened cylinders composed of various materials were compared in the current work. The structures under investigation were composed of titanium alloy, carbon fibre composite material, or a combination of both. A FEM model was proposed and validated by comparison with experimental results obtained from a composite material structure, and then it was used to simulate the behaviour of all the other structures. While there was some variation in the strength of the parts, it was discovered that the stiffness was almost uniform throughout all of the structures that were examined. But when the weight of the various constructions was taken into account, some very intriguing findings emerged: the composite material-only structure proved to be the most effective because it had the highest specific performances