Mixed-mode delamination growth prediction in stiffened CFRP panels by means of a novel fast procedure

Carbon fiber reinforced plastic (CFRP) structures are highly sensitive to delaminations, resulting from low energy impacts or manufacturing defects. Non-linear numerical algorithms are mandatory to investigate the complex mechanisms governing the delamination growth phenomena. Although the high computational costs associated to the non-linear algorithms are acceptable in a detail verification design stage, less expensive procedures are desired in a preliminary design stage or during optimization procedure. In this work, a fast numerical procedure, able to determine the delamination growth initiation in composite structures in the framework of a damage tolerant design approach when mixed mode I and II growth is expected, is introduced. The state of the art of the fast delamination growth procedures is critically discussed and improvements to the existing approaches are proposed to extend their applicability and to increase their accuracy. Comparisons with the standard non-linear delamination growth approaches are presented to assess the effectiveness of the proposed novel Fast approach. The results of the proposed fast approach are comparable with the ones obtained by means of standard numerical non-linear technique, allowing up to 95% computational cost saving

Application of an additive manufactured hybrid metal/composite shock absorber panel to a military seat ejection system

In this work, a preliminary numerical assessment on the application of an additive manufactured hybrid metal/composite shock absorber panels to a military seat ejection system, has been carried out. The innovative character of the shock absorber concept investigated is that the absorbing system has a thickness of only 6 mm and is composed of a pyramid‐shaped lattice core that, due to its small size, can only be achieved by additive manufacturing. The mechanical behaviour of these shock absorber panels has been examined by measuring their ability to absorb and dissipate the energy generated during the ejection phase into plastic deformations, thus reducing the loads acting on pilots. In this paper the effectiveness of a system composed of five hybrid shock absorbers, with very thin thickness in order to be easily integrated between the seat and the aircraft floor, has been numerically studied by assessing their ability to absorb the energy generated during the primary ejection phase. To accomplish this, a numerical simulation of the explosion has been performed and the energy absorbed by the shock‐absorbing mechanism has been assessed. The performed analysis demonstrated that the panels can absorb more than 60% of the energy generated during the explosion event while increasing the total mass of the pilot‐seat system by just 0.8%

Modelling the damage evolution in notched omega stiffened composite panels under compression

In this paper, the compressive behaviour of an omega stiffened composite panel with a large notch damage has been investigated. The influence of intra-laminar and inter-laminar damage onset and evolution on the compressive behaviour of a stiffened panel, characterised by a cut-out located in the middle bay and oriented at 45° with respect to the load direction, has been studied. A numerical model, taking into account delamination and fibre-matrix damage evolution, respectively, by means of cohesive elements and Hashin's failure criteria together with material degradation rules, has been adopted. By comparing the performed numerical analyses, taking into account intra-laminar and inter-laminar damages, the effects of the interaction between delaminations and fibre-matrix damage in the large notch area on the global compressive behaviour of the omega stiffened composite panel have been assessed and critically discussed

Cross-influence between intra-laminar damages and fibre bridging at the skin-stringer interface in stiffened composite panels under compression

In this paper, the skin-stringer separation phenomenon that occurs in stiffened composite panels under compression is numerically studied. Since the mode I fracture toughness and, consequently, the skin-stringer separation can be influenced by the fibre bridging phenomenon at the skin-stringer interface, in this study, comparisons among three different material systems with different fibre bridging sensitivities have been carried out. Indeed, a reference material system has been compared, in terms of toughness performance, against two materials with different degrees of sensitivity to fibre bridging. A robust numerical procedure for the delamination assessment has been used to mimic the skin-stringer separation. When analysing the global compressive behaviour of the stiffened panel, intra-laminar damages have been considered in conjunction with skin-stringer debonding to evaluate the effect of the fibre and matrix breakage on the separation between the skin and the stringer for the three analysed material systems. The latter are characterised by different toughness characteristics and fibre bridging sensitivities, resulting in a different material toughness

Dynamic pulse buckling of composite stanchions in the sub-cargo floor area of a civil regional aircraft

This work is focused on the investigation of the structural behavior of a composite floor beam, located in the cargo zone of a civil aircraft, subjected to cyclical low-frequency compressive loads with different amplitudes. In the first stage, the numerical models able to correctly simulate the investigated phenomenon have been defined. Different analyses have been performed, aimed to an exhaustive evaluation of the structural behavior of the test article. In particular, implicit and explicit analyses have been considered to preliminary assess the capabilities of the numerical model. Then, explicit non-linear analyses under time-dependent loads have been considered, to predict the behavior of the composite structure under cyclic loading conditions. According to the present investigation, low-frequency cyclic loads with peak values lower than the static buckling load value are not capable of triggering significant instability

A sensitivity analysis of the damage behavior of a leading-edge subject to bird strike

This paper aims to investigate the crashworthiness capability of a commercial aircraft metallic sandwich leading edge, subjected to bird strike events. A sensitivity analysis is presented, aimed to assess the influence of the skin parameters (inner and outer faces and core thicknesses) on the leading-edge crashworthiness and to determine, among the configurations able to withstand a bird strike event, the best compromise in terms of weight and structural performances. In order to easily manage the design parameters and the output data, the ModeFrontier code was used in conjunction with the FE code Abaqus/Explicit. A dedicated python routine was developed to define a fully parametric simplified leading-edge model. To fulfill the aerodynamic requirements, the external surfaces were considered fixed during the sensitivity analysis, and, thus, only the internal leading edge’s components were modified to study their influence on the structural response. The total mass of the model, the maximum deformation and the energy dissipated due to material failure and the plastic deformations were monitored and used to compare and assess the behavior of each configuration

A robust numerical methodology for fatigue damage evolution simulation in composites

Composite materials, like metals, are subject to fatigue effects, representing one of the main causes for component collapse in carbon fiber‐reinforced polymers. Indeed, when subject to low stress cyclic loading, carbon fiber‐reinforced polymers exhibit gradual degradation of the mechanical properties. The numerical simulation of this phenomenon, which can strongly reduce time and costs to market, can be extremely expensive in terms of computational effort since a very high number of static analyses need to be run to take into account the real damage propagation due the fatigue effects. In this paper, a novel cycle jump strategy, named Smart Cycle strategy, is introduced in the numerical model to avoid the simulation of every single cycle and save computational resources. This cycle jump strategy can be seen as an enhancement of the empirical model proposed by Shokrieh and Lessard for the evaluation of the fatigue‐induced strength and stiffness degradation. Indeed, the Smart Cycle allows quickly obtaining a preliminary assessment of the fatigue behavior of composite structures. It is based on the hypothesis that the stress redistribution, due to the fatigue‐induced gradual degradation of the material properties, can be neglected until sudden fiber and/or matrix damage is verified at element/lamina level. The numerical procedure has been implemented in the commercial finite element code ANSYS MECHANICAL, by means of Ansys Parametric Design Languages (APDL). Briefly, the Smart Cycle routine is able to predict cycles where fatigue failure criteria are likely to be satisfied and to limit the numerical simulation to these cycles where a consistent damage propagation in terms of fiber and matrix breakage is expected. The proposed numerical strategy was preliminarily validated, in the frame of this research study, on 30° fiber‐oriented unidirectional coupons subjected to tensile– tensile fatigue loading conditions. The numerical results were compared with literature experimental data in terms of number of cycles at failure for different percentage of the static strength. Lastly, in order to assess its potential in terms of computational time saving on more complex structures and different loading conditions, the proposed numerical approach was used to investigate the fatigue behavior of a cross‐ply open‐hole composite panel under tension–tension fatigue loading conditions

Numerical-experimental investigation into the tensile behavior of a hybrid metallic-CFRP stiffened aeronautical panel

In this work, the tensile behavior of a hybrid metallic-composite stiffened panel is investigated. The analyzed structure consists of an omega-reinforced composite fiber-reinforced plastic (CFRP) panel joined with a Z-reinforced aluminum plate by fasteners. The introduced numerical model, able to simulate geometrical and material non-linearities, has been preliminary validated by means of comparisons with experimental test results, in terms of strain distributions in both composite and metallic sub-components. Subsequently, the inter-laminar damage behavior of the investigated hybrid structure has been studied numerically by assessing the influence of key structural subcomponents on the damage evolution of an artificial initial debonding between the composite skin and stringers

Large Notch Damage Evolution in Omega Stiffened Composite Panels

The aim of this work is the study of the influence of a large notch damage in a stiffened aeronautical panel. In particular, the damage onset and evolution due to a cut-out located in the bay of an omega stiffened composite panel subjected to a compressive load is investigated. Three different cut-outs are considered: parallel, normal, and 45° oriented respect to the load. The effects of such configurations are compared in terms of fibre and matrix failures, in order to better understand which configuration is the most sensitive to these type of damages