Finite element analysis of hypervelocity impact behaviour of CFRP-Al/HC sandwich panel

The mechanical response of CFRP-Al/HC (carbon fibre-reinforced/epoxy composite face sheets with Al honeycomb core) sandwich panels to hyper-velocity impact (up to 1 km/s) is studied using a finite-element model developed in ABAQUS/Explicit. The intraply damage of CFRP face sheets is analysed by mean of a user-defined material model (VUMAT) employing a combination of Hashin and Puck criteria, delamination modelled using cohesive-zone elements. The damaged Al/HC core is assessed on the basis of a Johnson Cook dynamic failure model while its hydrodynamic response is captured using the Mie-Gruneisen equation of state. The results obtained with the developed finite-element model showed a reasonable correlation to experimental damage patterns. The surface peeling of both face sheets was evident, with a significant delamination around the impact location accompanied by crushing HC core

Effect of ultrasonically-assisted drilling on carbon-fibre-reinforced plastics

This research focuses on the effect of ultrasonically-assisted drilling (UAD) on carbon fibre-reinforced plastics. High-frequency vibration was used to excite a drill bit during its standard operation. An extensive experimental study of drilling forces, temperature, chip formation, surface finish, circularity, delamination and tool wear was conducted using ∅3 mm drill and presented here. UAD showed a significant improvement in drill quality when compared to conventional drilling processes. A finite-element study was also conducted to understand the nature of drilling-force reduction in UAD

Ballistic damage in hybrid composite laminates

Ballistic damage of hybrid woven-fabric composites made of plain-weave E-glass-fabric/epoxy and 8H satin-weave T300 carbon-fabric/epoxy is studied using a combination of experimental tests, microstructural studies and finite-element (FE) analysis. Ballistic tests were conducted with a single-stage gas gun. Fibre damage and delamination were observed to be dominating failure modes. A ply-level FE model was developed, with a fabric-reinforced ply modelled as a homogeneous orthotropic material with capacity to sustain progressive stiffness degradation due to fibre/matrix cracking, fibre breaking and plastic deformation under shear loading. Simulated damage patterns on the front and back faces of fabric-reinforced composite plates provided an insight into their damage mechanisms under ballistic loading

Impact and blast response of polymer matrix laminates- finite-element studies

Polymer matrix composites (PMCs) offer several advantages compared to traditional metallic counterparts when employed in high-performance products that need to be lightweight, yet strong enough to sustain harsh loading conditions - such as aerospace components and protective structures in military applications- armours, helmets, and fabrications retrofitted to transport vehicles and bunkers. These are often subjected to highly dynamic loading conditions under blast and ballistic impacts. Severe impact energy involved in these dynamic loading events can initiate discrete damage modes in PMCs such as matrix cracking, matrix splitting, delamination, fibre-matrix debonding, fibre micro-buckling and fibre pull-out. Interaction of these damage modes can severely reduce the load carrying capacity of such structures. This needs to be understood to design structures with improved resistance to such loading. [Continues.

Drilling in carbon/epoxy composites: experimental investigations and finite element implementation

Drilling carbon fibre reinforced plastics (CFRPs) is typically cumbersome due to high structural stiffness of the composite and low thermal conductivity of plastics. Resin-rich areas between neighbouring plies in a laminate are prone to drilling-induced delamination that compromises structural integrity. Appropriate selection of drilling parameters is believed to mitigate damage in CFRPs. In this context, we study the effect of cutting parameters on drilling thrust force and torque during the machining process both experimentally and numerically. A unique three-dimensional (3D) finite element model of drilling in a composite laminate, accounting for complex kinematics at the drill-workpiece interface is developed. Cohesive zone elements are used to simulate interply delamination in a composite. Experimental quantification of drilling-induced damage is performed by means of X-ray micro computed tomography. The developed numerical model is shown to agree reasonably well with the experiments. The model is used to predict optimal drilling parameters in carbon/epoxy composites