Assessment of Static Delamination Propagation Capabilities in Commercial Finite Element Codes Using Benchmark Analysis

With capabilities for simulating delamination growth in composite materials becoming available, the need for benchmarking and assessing these capabilities is critical. In this study, benchmark analyses were performed to assess the delamination propagation simulation capabilities of the VCCT implementations in Marc TM and MD NastranTM. Benchmark delamination growth results for Double Cantilever Beam, Single Leg Bending and End Notched Flexure specimens were generated using a numerical approach. This numerical approach was developed previously, and involves comparing results from a series of analyses at different delamination lengths to a single analysis with automatic crack propagation. Specimens were analyzed with three-dimensional and two-dimensional models, and compared with previous analyses using Abaqus . The results demonstrated that the VCCT implementation in Marc TM and MD Nastran(TradeMark) was capable of accurately replicating the benchmark delamination growth results and that the use of the numerical benchmarks offers advantages over benchmarking using experimental and analytical results

Development of a Finite Element Analysis Methodology for the Propagation of Delaminations in Composite Structures

Analysing the collapse of skin-stiffened structures requires capturing the critical phenomenon of skin-stiffener separation, which can be considered analogous to interlaminar cracking. This paper presents the development of a numerical approach for simulating the propagation of interlaminar cracks in composite structures. A degradation methodology was applied in MSC.Marc that involved modelling the structure with shell layers connected by user-defined multiple point constraints (MPCs). User subroutines were written that apply the Virtual Crack Closure Technique (VCCT) to determine the onset of crack growth, and modify the properties of the user-defined MPCs to simulate crack propagation. Methodologies for the release of failing MPCs are presented and are discussed with reference to the VCCT assumption of self-similar crack growth. Numerical results applying the release methodologies are then compared with experimental results for a double cantilever beam specimen. Based on this comparison, recommendations for the future development of the degradation model are made, especially with reference to developing an approach for the collapse analysis of fuselage-representative structures

Development of a Degradation Model for the Collapse Analysis of Composite Aerospace Structures

For stiffened structures in compression the most critical damage mechanism leading to structural collapse is delamination or adhesive disbonding between the skin and stiffener. This paper presents the development of a numerical approach capable of simulating interlaminar crack growth in composite structures as a representation of this damage mecha-nism. A degradation methodology was proposed using shell layers connected at the nodes by user-defined multiple point constraints (MPCs), and then controlling the properties of these MPCs to simulate the initiation and propagation of delamination and disbonding. A fracture mechanics approach based on the Virtual Crack Closure Technique (VCCT) is used to detect growth at the delamination front. Numerical predictions using the degradation methodology were compared to experimental results for double cantilever beam (DCB) specimens to dem-onstrate the effectiveness of the current approach. Future development will focus on address-ing the apparent conservatism of the VCCT approach, and extending the application of the method to other specimen types and stiffened structures representative of composite fuselage designs. This work is part of the European Commission Project COCOMAT (Improved MA-Terial Exploitation at Safe Design of COmposite Airframe Structures by Accurate Simulation of COllapse), an ongoing four-year project that aims to exploit the large strength reserves of composite aerospace structures through more accurate prediction of collapse

Nonlinear static analysis of composite beams with piezoelectric actuator patches using the Refined Zigzag Theory

Piezoelectric actuators have been highly successful in a wide range of structural control applications. Assuch, there is an ongoing need for rapid and accurate structural analysis techniques, particularly for highlyheterogeneous composite materials and accounting for the actuator as a patch.Here, a new model based on the Refined Zigzag Theory (RZT) formulation that includes geometricnonlinearities is proposed for buckling, postbuckling and nonlinear static response analyses of geometricallyimperfect composite beams with piezoelectric actuators.Both the analytical and the finite element (FE) formulation are presented for symmetrically and non-symmetrically laminated beams. The FE approximation is further generalised to the case of beams withgeometric discontinuities to model composite beams with piezoelectric actuator patches. The new RZT modelis numerically verified through comparisons to Abaqus solutions for buckling and postbuckling analyses andfor the geometrically nonlinear response to an applied voltage of geometrically imperfect composite beamswith piezoelectric actuator patches.This work presents a new model for composite beams with piezoelectric actuators and confirms theremarkable advantages of RZT in terms of accuracy and computational efficiency also for challenging nonlinearanalyses, where the RZT computational time is generally less than half the time required by the FE commercial code

Development of a finite element methodology for the propagation of delaminations in composite structures

Analysing the collapse of skin-stiffened structures requires capturing the critical phenomenon of skin-stiffener separation, which can be considered analogous to interlaminar cracking. This paper presents the development of a numerical approach for simulating the propagation of interlaminar cracks in composite structures. A degradation methodology was introduced in MSC.Marc, which involved the modelling of a structure with shell layers connected by user-defined multiple-point constraints (MPCs). User subroutines were written that employ the virtual crack closure technique (VCCT) to determine the onset of crack growth and modify the properties of the user-defined MPCs to simulate crack propagation. Methodologies for the release of failing MPCs are presented and are discussed with reference to the VCCT assumption of self-similar crack growth. The numerical results obtained by using the release methodologies are then compared with experimental data for a double-cantilever beam specimen. Based on this comparison, recommendations for the future development of the degradation model are made, especially with reference to developing an approach for the collapse analysis of fuselage-representative structures

AN ANALYSIS TOOL FOR DESIGN AND CERTIFICATION OF POSTBUCKLING COMPOSITE AEROSPACE STRUCTURES

In aerospace, carbon fibre-reinforced polymer (CFRP) composites and postbuckling skin-stiffened structures are key technologies that have been used to improve structural efficiency. However, the application of composite postbuckling structures in aircraft has been limited due to concerns related to both the durability of composite structures and the accuracy of design tools. In this work, a finite element analysis tool for design and certification of aerospace structures is presented, which predicts collapse by taking the critical damage mechanisms into account. The tool incorporates a global-local analysis technique for predicting interlaminar damage initiation, and degradation models to capture the growth of a pre-existing interlaminar damage region, such as a delamination or skin-stiffener debond, and in-plane ply damage mechanisms such as fibre fracture and matrix cracking. The analysis tool has been applied to single- and multi-stiffener fuselage-representative composite panels, in both intact and pre-damaged configurations. This has been performed in a design context, in which panel configurations are selected based on their suitability for experimental testing, and in an analysis context for comparison with experimental results as representative of aircraft certification studies. For all cases, the tool was capable of accurately capturing the key damage mechanisms contributing to final structural collapse, and suitable for the design of next-generation composite aerospace structures

High strain rate and high temperature response of two armour steels: Experimental testing and constitutive modelling

Under ballistic impact or blast loading, the high strain rate and high temperature behaviour of armour steels is key to their response to a given threat. This experimental and numerical investigation examines the tensile response of a class 4a improved rolled homogenous armour steel (IRHA) and a high hardness armour steel (HHA). Cylindrical tensile specimens were tested at a range of strain rates from 0.001 s-1 to 2700 s-1. Quasi-static, elevated temperature tests were performed from room temperature up to 300° C. While the HHA is strain rate insensitive, the IRHA displays a significant increase in strength across the range of loading rates reducing the ultimate strength difference between the materials from 19% at 0.001s-1 to 4.6% at 2700s-1. An inverse numerical modelling approach for constitutive model calibration is presented, which accurately captured the dynamic material behaviour. The modified Johnson-Cook strength and Cockcroft-Latham (C-L) fracture models were capable of predicting the ballistic limit of each material to within 5% of the experimental result and to within 10% for deformation under blast loading. The blast rupture threshold of both materials was significantly over-estimated by the C-L model suggesting stress state or strain rate effects may be reducing the ductility of armour steel under localised blast loading

High strain rate and high temperature response of two armour steels: Experimental testing and constitutive modelling

Under ballistic impact or blast loading, the high strain rate and high temperature behaviour of armour steels is key to their response to a given threat. This experimental and numerical investigation examines the tensile response of a class 4a improved rolled homogenous armour steel (IRHA) and a high hardness armour steel (HHA). Cylindrical tensile specimens were tested at a range of strain rates from 0.001 s-1 to 2700 s-1. Quasi-static, elevated temperature tests were performed from room temperature up to 300° C. While the HHA is strain rate insensitive, the IRHA displays a significant increase in strength across the range of loading rates reducing the ultimate strength difference between the materials from 19% at 0.001s-1 to 4.6% at 2700s-1. An inverse numerical modelling approach for constitutive model calibration is presented, which accurately captured the dynamic material behaviour. The modified Johnson-Cook strength and Cockcroft-Latham (C-L) fracture models were capable of predicting the ballistic limit of each material to within 5% of the experimental result and to within 10% for deformation under blast loading. The blast rupture threshold of both materials was significantly over-estimated by the C-L model suggesting stress state or strain rate effects may be reducing the ductility of armour steel under localised blast loading