Analysis of cracks emanating from a circular hole in unidirectional fiber reinforced composites, part 2

An analytical method is developed for cracks emanating from a circular hole in an off-axis unidirectional fiber-reinforced composite. The method which is formulated by using conservation laws of elasticity and fundamental relationships in anisotropic fracture mechanics, provides a convenient and accurate means to examine the complicated crack behavior, when used in conjunction with a suitable numerical scheme such as the finite element method. The formulation is eventually reduced to a system of linear algebraic equations of mixed-mode stress intensity factors. Fracture parameters, describing crack-tip deformation and fracture in the composite, are obtained explicitly. Effects of material anisotropy and crack/hole geometry are examined also. Of particular interest are the energy release rates associated with crack extension; their values are evaluated for various cases. Results show that mixed-mode stress intensity factors and energy release rates associated with the cracks emanating from a hole change very appreciably with fiber orientation in the composite. K sub 1 and G increase monotonically with increasing theta; but K sub 2 reaches its maximum at theta = 45 deg, and then decreases gradually as theta increases further

Fatigue life assessment of notched laminated composites: Experiments and modelling by Finite Fracture Mechanics

In this paper, the coupled Finite Fracture Mechanics criterion is extended to assess the finite fatigue life of orthotropic notched laminated composites. The approach is validated through a comprehensive experimental program conducted on laminated composites under tension-tension cyclic loading conditions with two distinct lay-ups. For a given loading ratio, fatigue tests on plain and cracked specimens are first performed to provide the model inputs, the critical cyclic stress and stress intensity factor amplitudes. Fatigue tests on samples weakened by circular holes of two different radii are then used for blind predictions. Accurate predictions of the number of cycles to failure are achieved without the need for inverse calibration of material properties or deviation from standard testing procedures. Finally, a parametric study is performed to investigate the hole radius effect. It is worth mentioning that the proposed approach is general and can be applied to any notched geometry

NASA Langley developments in response calculations needed for failure and life prediction

NASA Langley developments in response calculations needed for failure and life predictions are discussed. Topics covered include: structural failure analysis in concurrent engineering; accuracy of independent regional modeling demonstrated on classical example; functional interface method accurately joins incompatible finite element models; interface method for insertion of local detail modeling extended to curve pressurized fuselage window panel; interface concept for joining structural regions; motivation for coupled 2D-3D analysis; compression panel with discontinuous stiffener coupled 2D-3D model and axial surface strains at the middle of the hat stiffener; use of adaptive refinement with multiple methods; adaptive mesh refinement; and studies on quantity effect of bow-type initial imperfections on reliability of stiffened panels

Delamination micromechanics analysis

A three-dimensional finite element analysis was developed which includes elastoplastic, orthotropic material response, and fracture initiation and propagation. Energy absorption due to physical failure processes characteristic of the heterogeneous and anisotropic nature of composite materials is modeled. A local energy release rate in the presence of plasticity was defined and used as a criterion to predict the onset and growth of cracks in both micromechanics and macromechanics analyses. This crack growth simulation technique is based upon a virtual crack extension method. A three-dimensional finite element micromechanics model is used to study the effects of broken fibers, cracked matrix and fiber-matrix debond on the fracture toughness of the unidirectional composite. The energy release rates at the onset of unstable crack growth in the micromechanics analyses are used as critical energy release rates in the macromechanics analysis. This integrated micromechanical and macromechanical fracture criterion is shown to be very effective in predicting the onset and growth of cracks in general multilayered composite laminates by applying the criterion to a single-edge notched graphite/epoxy laminate subjected to implane tension normal to the notch

A global/local analysis method for treating details in structural design

A method for analyzing global/local behavior of plate and shell structures is described. In this approach, a detailed finite element model of the local region is incorporated within a coarser global finite element model. The local model need not be nodally compatible (i.e., need not have a one-to-one nodal correspondence) with the global model at their common boundary; therefore, the two models may be constructed independently. The nodal incompatibility of the models is accounted for by introducing appropriate constraint conditions into the potential energy in a hybrid variational formulation. The primary advantage of this method is that the need for transition modeling between global and local models is eliminated. Eliminating transition modeling has two benefits. First, modeling efforts are reduced since tedious and complex transitioning need not be performed. Second, errors due to the mesh distortion, often unavoidable in mesh transitioning, are minimized by avoiding distorted elements beyond what is needed to represent the geometry of the component. The method is applied reduced to a plate loaded in tension and transverse bending. The plate has a central hole, and various hole sixes and shapes are studied. The method is also applied to a composite laminated fuselage panel with a crack emanating from a window in the panel. While this method is applied herein to global/local problems, it is also applicable to the coupled analysis of independently modeled components as well as adaptive refinement

Strength prediction of notched thin ply laminates using finite fracture mechanics and the phase field approach

Thin ply laminates are a new class of composite materials with great potential for application in the design of thinner and highly optimized components, resulting in potential weight savings and improved mechanical performance. These new composites can stir the development of lighter structures, overcoming current design limitations as well as notably reducing the onset and development of matrix cracking and delamination events. This paper presents the application of two recent modeling methods for the failure analysis and strength prediction of open-hole thin ply laminates under tensile loading, which exhibit a brittle response upon failure: (i) the analytical coupled energy-stress Finite Fracture Mechanics (FFMs) technique, and (ii) the FE-based Phase Field (PF) approach for fracture that is incorporated into an enhanced assumed solid shell element. The predictions obtained using both strategies are compared with experimental data. These correlations exhibit a very satisfactory level of agreement, proving the robustness and reliability of both methods under consideration

Damage characterization and modeling of notched graphite/epoxy sandwich panels in compression

Thesis (S.M.)--Massachusetts Institute of Technology, Dept. of Aeronautics and Astronautics, 1999.Includes bibliographical references (leaves 129-133).Damage tolerant design, which focuses on a structure's ability to perform in a damaged state, is widely used in the aerospace industry today. Although extensive research has been carried out in this area for notched composite laminates, a relatively small fraction has dealt with compressive loading of composite honeycomb sandwich panels. Furthermore, little emphasis has been placed on identifying and modeling the damage mechanisms that contribute to ultimate failure. In an attempt to better understand the damage propagation and residual properties of notched composite panels subjected to compressive loads, edge-wise uniaxial quasi-static tests were performed in displacement control. Coupons consisted of various sized notched sandwich panels with woven Graphite-reinforced PMC facesheets and Nomex honeycomb cores. Two lay-ups were used in the facesheets: [45/0/0] and [0/0/0/], identified as T45 and TO respectively for simplicity. Damage propagated in all coupons perpendicular to the load direction from one or more of the four notch tips. All coupons were loaded to final failure. In-situ and post-mortem damage evaluation techniques such as polishing and microscopy were employed to describe the damage progression. The key microscopic damage mechanisms were identified to be delamination and fiber micro-buckling, which often led to kinkband formation. Two distinct failure types were identified macroscopically: linear damage zones (LDZ's) and delamination/bulge zones (DBZ's), the latter being confined to the T45 series. The LDZ's consisted of out-of-plane kink-bands propagating away from the notch in the 00 plies, and were modeled using a bridged-crack analogy with tensile loading (DZM). The DBZ's were formed by the outer 450 ply, which delaminated from the rest of the coupon and buckled locally into a deformed out-of-plane curved shape. They were described using a novel one-dimensional delamination/buckling propagation model (DBM). Comparison between the two models revealed that smaller panels were more prone to linear damage zone formation, whereas larger panels were more prone to delamination/buckling zone formation. Damage mechanism charts were produced which are capable of predicting the operative damage mechanism as a function of material and geometric parameters.by José María Mirazo Antolín.S.M

Failure Analysis and Mechanisms of Failure of Fibrous Composite Structures

The state of the art of failure analysis and current design practices, especially as applied to the use of fibrous composite materials in aircraft structures is discussed. Deficiencies in these technologies are identified, as are directions for future research

Prediction of delamination in glass fibre reinforced composite materials using elasto-plastic modelling

Glass Fibre reinforced composite (GFRC) has been used for numerous structural applications in Aerospace, Chemical, Automotive and Civil infrastructure fields over a hundred of years. Due to this reason, understanding the intricate fracture behaviour of GFRC materials is crucial and essential for designing critical structural components. Voids and micro-cracks are considered as imperfections in Glass Fibre Reinforced composites. Much research has been undertaken on approaches to calculate and evaluate the effects of the imperfections on mechanical properties. However, it is an established fact that the micro-mechanical approach alone is not sufficient to understand a complete damage accumulation process during delamination. The damage mechanism which largely affects the performance of GFRC structures is commonly known as 'delamination'. Since the delamination is invisible, and hard to detect with ordinary non-destructive evaluation methods, therefore it is considered as a hidden killer which can cause catastrophic failure without any prior warnings. Due to this reason, research work on delamination modelling, damage detection and self-healing materials have been the highly placed research topics for more than five decades. Unfortunately there are a number of unresolved problems in delamination damage modelling and prediction, and few grey areas regarding application of Structural Health Monitoring systems to monitor delamination damages. This thesis has proposed to study the insight into the cause of delamination damage and its propagation mechanisms, by analytical modelling and experimental verifications. Within this research project, extension of the work by Tsukrov and Kachanov (2000) – “An innovative Elasto-plastic model” has been undertaken to evaluate, investigate and model the onset and propagation of delamination damages. Mode I, Mode II as well as Mixed Mode I/II delamination damage analysis has been utilised to study the proposed model predictions for GFRC structures for both in-plane and out-of-plane load applications. The proposed model has been validated using the Double Cantilever Beam (DCB), End Notch Flexure configurations (ENF) and Cracked Lap Shear (CLS) experiments on 0/90-glass woven cloth specimens. For the validation process, the procedures stipulated by ASTM standards were employed. It was observed that there were significant discrepancies between calculated fracture energies using standard procedures and the proposed model. Interestingly these observations have revealed some inconsistencies associated with the standard method for strain measurements that majorly controls the fracture energy calculations. This research project has demonstrated and evidently proven the accuracy of the proposed model predictions using the strain measured with embedded Fibre Bragg Grating (FBG) sensors, located inside the sample in proximity of the crack tip. The extended use of FBG strain measurement has created a breakthrough in Structural Health Monitoring (SHM) of composite structures. Non-availability of a suitable damage prediction model is an issue for accurate damage monitoring process. The proposed model has also demonstrated the potential for its integration with Structural Health Monitoring (SHM) systems. Additionally, Thermoplastic Stress Analysis (TSA) has been employed to monitor delamination. The potential for integration of FBG sensors and TSA techniques has been experimentally demonstrated during this project and, it is another breakthrough in SHM field as a result of this research. In addition to analytical model, a detailed Finite Element model was also created on ABAQUS commercial software. The cohesive elements with state variables (SDV) and UMAT codes were used for FEA simulations. Interestingly, the FEA results have shown an excellent correlation with the experimental results. Finally, this thesis has evidently proved the validity of the proposed model and integration of model with SHM system based on FBG sensors and TSA techniques. The outcomes of the thesis have provided a novel and innovative damage prediction model and a breakthrough technology for SHM systems