Guidelines and Parameter Selection for the Simulation of Progressive Delamination

Turon s methodology for determining optimal analysis parameters for the simulation of progressive delamination is reviewed. Recommended procedures for determining analysis parameters for efficient delamination growth predictions using the Abaqus/Standard cohesive element and relatively coarse meshes are provided for single and mixed-mode loading. The Abaqus cohesive element, COH3D8, and a user-defined cohesive element are used to develop finite element models of the double cantilever beam specimen, the end-notched flexure specimen, and the mixed-mode bending specimen to simulate progressive delamination growth in Mode I, Mode II, and mixed-mode fracture, respectively. The predicted responses are compared with their analytical solutions. The results show that for single-mode fracture, the predicted responses obtained with the Abaqus cohesive element correlate well with the analytical solutions. For mixed-mode fracture, it was found that the response predicted using COH3D8 elements depends on the damage evolution criterion that is used. The energy-based criterion overpredicts the peak loads and load-deflection response. The results predicted using a tabulated form of the BK criterion correlate well with the analytical solution and with the results predicted with the user-written element

Experimental and Numerical Analysis of Skin-Stiffener Separation Using a Seven-Point Bend Configuration

Skin-stiffener separation in stiffened composite panels consists of a complex interaction between multiple scales of progressive damage and failure mechanisms. This work used a superposed cohesive element method of modeling resistance curve effects that represents the structural interface of a unidirectional tape skin and a fabric stiffener. Finite element models using cohesive elements with input properties obtained from tape-to-fabric interface characterization tests were compared to experimental results of a stable skin-stiffener separation characterization test using a seven-point bend fixture. This fixture deformed the stiffened panel specimens into a buckled configuration which induced mixed-mode interlaminar stress states at the skin-stiffener interface. The advantage of this fixture was the potential for more stable damage initiation and delamination growth compared to a stringer-stiffened panel under axial compression. Use of the superposed cohesive elements showed promise, but the characterization of interface material properties as input to the cohesive elements remains a crucial component to be investigated to ensure accurate prediction of skin-stiffener separation

Fracture Mechanics Analyses of Subsurface Defects in Reinforced Carbon-Carbon Joggles Subjected to Thermo-Mechanical Loads

Coating spallation events have been observed along the slip-side joggle region of the Space Shuttle Orbiter wing-leading-edge panels. One potential contributor to the spallation event is a pressure build up within subsurface voids or defects due to volatiles or water vapor entrapped during fabrication, refurbishment, or normal operational use. The influence of entrapped pressure on the thermo-mechanical fracture-mechanics response of reinforced carbon-carbon with subsurface defects is studied. Plane-strain simulations with embedded subsurface defects are performed to characterize the fracture mechanics response for a given defect length when subjected to combined elevated-temperature and subsurface-defect pressure loadings to simulate the unvented defect condition. Various subsurface defect locations of a fixed-length substrate defect are examined for elevated temperature conditions. Fracture mechanics results suggest that entrapped pressure combined with local elevated temperatures have the potential to cause subsurface defect growth and possibly contribute to further material separation or even spallation. For this anomaly to occur, several unusual circumstances would be required making such an outcome unlikely but plausible

Space Shuttle Orbiter Wing-Leading-Edge Panel Thermo-Mechanical Analysis for Entry Conditions

Linear elastic, thermo-mechanical stress analyses of the Space Shuttle Orbiter wing-leading-edge panels is presented for entry heating conditions. The wing-leading-edge panels are made from reinforced carbon-carbon and serve as a part of the overall thermal protection system. Three-dimensional finite element models are described for three configurations: integrated configuration, an independent single-panel configuration, and a local lower-apex joggle segment. Entry temperature conditions are imposed and the through-the-thickness response is examined. From the integrated model, it was concluded that individual panels can be analyzed independently since minimal interaction between adjacent components occurred. From the independent single-panel model, it was concluded that increased through-the-thickness stress levels developed all along the chord of a panel s slip-side joggle region, and hence isolated local joggle sections will exhibit the same trend. From the local joggle models, it was concluded that two-dimensional plane-strain models can be used to study the influence of subsurface defects along the slip-side joggle region of these panels

Fracture Mechanics Analyses of the Slip-Side Joggle Regions of Wing-Leading Edge Panels

The Space Shuttle Orbiter wing comprises of 22 leading edge panels on each side of the wing. These panels are part of the thermal protection system that protects the Orbiter wings from extreme heating that take place on the reentry in to the earth atmosphere. On some panels that experience extreme heating, liberation of silicon carbon (SiC) coating was observed on the slip side regions of the panels. Global structural and local fracture mechanics analyses were performed on these panels as a part of the root cause investigation of this coating liberation anomaly. The wing-leading-edge reinforced carbon-carbon (RCC) panels, Panel 9, T-seal 10, and Panel 10, are shown in Figure 1 and the progression of the stress analysis models is presented in Figure 2. The global structural analyses showed minimal interaction between adjacent panels and the T-seal that bridges the gap between the panels. A bounding uniform temperature is applied to a representative panel and the resulting stress distribution is examined. For this loading condition, the interlaminar normal stresses showed negligible variation in the chord direction and increased values in the vicinity of the slip-side joggle shoulder. As such, a representative span wise slice on the panel can be taken and the cross section can be analyzed using plane strain analysis

Fracture Mechanics Analyses of Reinforced Carbon-Carbon Wing-Leading-Edge Panels

Fracture mechanics analyses of subsurface defects within the joggle regions of the Space Shuttle wing-leading-edge RCC panels are performed. A 2D plane strain idealized joggle finite element model is developed to study the fracture behavior of the panels for three distinct loading conditions - lift-off and ascent, on-orbit, and entry. For lift-off and ascent, an estimated bounding aerodynamic pressure load is used for the analyses, while for on-orbit and entry, thermo-mechanical analyses are performed using the extreme cold and hot temperatures experienced by the panels. In addition, a best estimate for the material stress-free temperature is used in the thermo-mechanical analyses. In the finite element models, the substrate and coating are modeled separately as two distinct materials. Subsurface defects are introduced at the coating-substrate interface and within the substrate. The objective of the fracture mechanics analyses is to evaluate the defect driving forces, which are characterized by the strain energy release rates, and determine if defects can become unstable for each of the loading conditions

Elastic-Plastic Nonlinear Response of a Space Shuttle External Tank Stringer

Elastic-plastic, large-deflection nonlinear thermo-mechanical stress analyses are performed for the Space Shuttle external tank s intertank stringers. Detailed threedimensional finite element models are developed and used to investigate the stringer s elastic-plastic response for different thermal and mechanical loading events from assembly through flight. Assembly strains caused by initial installation on an intertank panel are accounted for in the analyses. Thermal loading due to tanking was determined to be the bounding loading event. The cryogenic shrinkage caused by tanking resulted in a rotation of the intertank chord flange towards the center of the intertank, which in turn loaded the intertank stringer feet. The analyses suggest that the strain levels near the first three fasteners remain sufficiently high that a failure may occur. The analyses also confirmed that the installation of radius blocks on the stringer feet ends results in an increase in the stringer capability

FAST Mast Structural Response to Axial Loading: Modeling and Verification

The International Space Station s solar array wing mast shadowing problem is the focus of this paper. A building-block approach to modeling and analysis is pursued for the primary structural components of the solar array wing mast structure. Starting with an ANSYS (Registered Trademark) finite element model, a verified MSC.Nastran (Trademark) model is established for a single longeron. This finite element model translation requires the conversion of several modeling and analysis features for the two structural analysis tools to produce comparable results for the single-longeron configuration. The model is then reconciled using test data. The resulting MSC.Nastran (Trademark) model is then extended to a single-bay configuration and verified using single-bay test data. Conversion of the MSC. Nastran (Trademark) single-bay model to Abaqus (Trademark) is also performed to simulate the elastic-plastic longeron buckling response of the single bay prior to folding

Material Characterization for the Analysis of Skin/Stiffener Separation

Test results show that separation failure in co-cured skin/stiffener interfaces is characterized by dense networks of interacting cracks and crack path migrations that are not present in standard characterization tests for delamination. These crack networks result in measurable large-scale and sub-ply-scale R curve toughening mechanisms, such as fiber bridging, crack migration, and crack delving. Consequently, a number of unknown issues exist regarding the level of analysis detail that is required for sufficient predictive fidelity. The objective of the present paper is to examine some of the difficulties associated with modeling separation failure in stiffened composite structures. A procedure to characterize the interfacial material properties is proposed and the use of simplified models based on empirical interface properties is evaluated

Postbuckling and Growth of Delaminations in Composite Plates Subjected to Axial Compression

The postbuckling response and growth of circular delaminations in flat and curved plates are investigated as part of a study to identify the criticality of delamination locations through the laminate thickness. The experimental results from tests on delaminated plates are compared with finite element analysis results generated using shell models. The analytical prediction of delamination growth is obtained by assessing the strain energy release rate results from the finite element model and comparing them to a mixed-mode fracture toughness failure criterion. The analytical results for onset of delamination growth compare well with experimental results generated using a 3-dimensional displacement visualization system. The record of delamination progression measured in this study has resulted in a fully 3-dimensional test case with which progressive failure models can be validated