Impacts on foam stabilised composite structures: experimental and numerical study

A dropweight tester is used to make low velocity tests on specific sandwich type structures. Sandwich are made of glass-epoxy skin and polyurethane foam core. The skins can be straight or little curved, and impact direction is the global skin direction. The aim of these tests is to study the initiation of rupture in such structures :local buckling of skin and foam core rupture. Experimental results are given. They show the evolution of buckling critical stress in the skin when impact velocity increases. The rupture mode in curved skin specimen is also studied : rupture is no more provoked by buckling. A numerical analysis is proposed to model the behaviour of the structure and the rupture initiation. Finally, a method is developed, in order to predict the propagation of skin debonding during impact : an element layer under the skin is damaged with a specific law to simulate debonding

Dynamic buckling of foam stabilised composite skin

Presented in the following pages is an experimental and numerical study of dynamic local buckling of skin on foam core. Impact tests on sandwich-type structures with skins stabilized by foam demonstrated that rupture appears by debonding of skins due to a local buckling phenomenon, and that the maximum stress in the skin, obtained at rupture, grows with the increase of the loading rate of the skin. A finite element analysis allows this phenomenon to be analyzed and understood, and a mass-spring-dashpot model is proposed to model the skin debonding initiation

Buckling of foam stabilised composite structures

An analytical modelling of the symmetrical wrinkling is proposed : from original assumptions on displacements within the core, and from an energy minimisation method, it is possible to predict critical loads and buckling modes better than traditional models do, and to distinguish the influence of each structure component. Compression tests were carried out on sandwich structures to validate the model. Little curved structures were also tested to estimate the influence of skin curvature on rupture and buckling mode. A finite elements analysis has been achieved in parallel : a fine modelling allows to find results close to experimental ones

Low velocity impact modeling in composite laminates capturing permanent indentation

This paper deals with impact damage and permanent indentation modeling. A numerical model has been elaborated in order to simulate the different impact damage types developing during low velocity/low energy impact. The three current damage types: matrix cracking, fiber failure and delamination, are simulated. Inter-laminar damage, i.e. interface delamination, is conventionally simulated using interface elements based on fracture mechanics. Intra-laminar damage, i.e. matrix cracks, is simulated using interface elements based on failure criterion. Fiber failure is simulated using degradation in the volume elements. The originality of this model is to simulate permanent indentation after impact with a ‘‘plastic-like’’model introduced in the matrix cracking elements. This model type is based on experimental observations showing matrix cracking debris which block crack closure. Lastly, experimental validation is performed, which demonstrates the model’s satisfactory relevance in simulating impact damage. This acceptable match between experiment and modeling confirms the interest of the novel approach proposed in this paper to describe the physics behind permanent indentation

Modelling of impact damage and permanent indentation on laminate composite plate

This paper deals with impact damage and permanent indentation modelling. A model enabling the formation of damages developing during a low velocity / low energy impact test on laminate composite panels has been elaborated. The different impact damages developing during an impact test, i.e. matrix cracking, fibres failure and interfaces delamination, are simulated. The interlaminar damages, i.e. interfaces delamination, are classically simulated thanks to interface finite elements based on the fracture mechanics. The particularity of this model is to account for the intralaminar damages, i.e. matrix cracks, thanks to interface finite elements which respect their discontinue character. These interface elements allow equally to simulate the permanent indentation during the impact unloading. This impact mark modelling is very original in the literature, and should allow to entirely design a composite structure thanks to impact damage tolerance

Experimental investigation on mean crushing stress characterization of carbon–epoxy plies under compressive crushing mode

A challenge in numerical simulation of crashworthiness study is to be able to predict the crush damage modes, their evolution during crushing and the energy absorption in any composite structure from elementary material characterisation data. Therefore, it is important to know the behavior of one ply subjected to crushing load, and especially to determine the mean crushing stress that could be used for simulation. For that purpose, quasi-static crushing tests are performed for different configurations of two CFRP materials, UD and fabrics to determine the mean crushing stress of plies alone and inside a laminate. This study shows there is a linear relationship between crushing load and the contact surface of the plies being crushed on a metallic base which enables actually to define a mean crushing stress for a ply. The method to calculate this value is presented in this paper, based on image analysis of specific crushing tests. Experimental results show that for the UD material, the mean crushing stresses in 0° and 90° plies are very close. The value for a balanced fabric is also similar, approximately 270 MPa

Core crush criterion to determine the strength of sandwich composite structures subjected to compression after impact

In this study a core crush criterion is proposed to determine the residual strength of impacted sandwich structures. The core of the sandwich is made of a Nomex Honeycomb core and the faces are laminated and remain thin. The mechanism of failure of this kind of structure under post-impact compressive loading is due to interaction between three mechanical behaviors: geometrical nonlinearity due to the skin’s neutral line off-set in the dent area, nonlinear response of the core and damages to the skins. For the type of sandwich analysed in this study, initially the core crushes at the apex of the damage. Using a finite element discrete modelling of the core previously proposed by the authors, the load corresponding to the crushing of the first cell can be computed and it gives the value of the residual strength for our criterion. Some geometric and material hypotheses are assumed in the damaged area mainly based on nondestructive inspection (NDI). The criterion is then applied to tests modelled by Lacy and Hwang [Lacy TE, Hwang Y. Numerical modelling of impact-damaged sandwich composites subjected to compression after impact loading. Compos Struct 2003;61:115–128]. It is shown that the criterion allows a good prediction of the tests except in the case of very small dents. Several sensitivity studies on the assumptions were made and it is shown that using this approach, the criterion is robust

Fatigue crack growth in thin notched woven glass composites under tensile loading. Part I: experimental

Helicopter blades are made of composite materials mainly loaded in fatigue and have normally relatively thin skins. A through-the-thickness crack could appear in these skins. The aim of this study is to characterize the through-the-thickness crack propagation due to fatigue in thin woven glass fabric laminates. A technological test specimen is developed to get closer to the real loading conditions acting on these structures. An experimental campaign is undertaken which allows evaluating crack growth rates in several laminates. The crack path is linked through microscopic investigations to specify damage in woven plies. Crack initiation duration influence on experimental results is also underlined

Fatigue crack growth in thin notched woven glass composites under tensile loading. Part II: modelling

Fatigue propagation of a through-the-thickness crack in thin woven glass laminates is difficult to model when using homogeneous material assumption. Crack growth depends on both the fatigue behaviour of the fibres and of the matrix, these two phenomena occurring at different time and space scales. The developed finite element model is based on the architecture of the fabric and on the fatigue behaviours of the matrix and the fibre, even if the pure resin and fibre behaviours are not used. That thus limits the physical meaning of this model. Basically, the objective of this simulation is to illustrate and to confirm proposed crack growth mechanism. The fatigue damage matrix is introduced with user spring elements that link the two fibre directions of the fabric. Fibre fatigue behaviour is based on the S-N curves. Numerical results are compared to experimental crack growth rates and observed damage in the crack tip. Relatively good agreement between predictions and experiments was found

Influence of woven ply degradation on fatigue crack growth in thin notched composites under tensile loading

This paper deals with the fatigue of the through the-thickness crack propagation in thin notched composite laminates made of two glass woven plies. It highlights the different crack growths between warp and weft directions of the woven ply. Experimental results show a decrease of the crack growth rate per cycle with the increase of the crack initiation time. Moreover, it has been shown that it is necessary to take into account the fatigue damage of the woven plies in term of loss of rigidity in the initiation phase. The fatigue crack growth rates are then quantified using Paris law type equations and linear elastic fracture mechanics (LEFM)