Implementation of a Matrix Crack Spacing Parameter in a Continuum Damage Mechanics Finite Element Model

Continuum Damage Mechanics (CDM) based progressive damage and failure analysis (PDFA) methods have demonstrated success in a variety of finite element analysis (FEA) implementations. However, the technical maturity of CDM codes has not yet been proven for the full design space of composite materials in aerospace applications. CDM-based approaches represent the presence of damage by changing the local material stiffness definitions and without updating the original mesh or element integration schemes. Without discretely representing cracks and their paths through the mesh, damage in models with CDM-based materials is often distributed in a region of partially damaged elements ahead of stress concentrations. Having a series of discrete matrix cracks represented by a softened region may affect predictions of damage propagation and, thus, structural failure. This issue can be mitigated by restricting matrix damage development to discrete, fiber-aligned rows of elements; hence CDM-based matrix cracks can be implemented to be more representative of discrete matrix cracks. This paper evaluates the effect of restricting CDM matrix crack development to discrete, fiber-aligned rows where the spacing of these rows is controlled by a user-defined crack spacing parameter. Initially, the effect of incrementally increasing matrix crack spacing in a unidirectional center notch coupon is evaluated. Then, the lessons learned from the center notch specimen are applied to open-hole compression finite element models. Results are compared to test data, and the limitations, successes, and potential of the matrix crack spacing approach are discussed

Investigation of Stiffening and Curvature Effects on the Residual Strength of Composite Stiffened Panels with Large Transverse Notches

Design of robust aircraft structure requires consideration of the load-carrying capability with large damage. Large notches, typically introduced as machined cracks (aka "notches") severing a single skin bay and a central stiffening member, are often used to conservatively address the wide range of possible large damage scenarios. The objective of the current effort was to develop more generalized and rapid analysis methods addressing large-notch residual strength of stiffened panels to support preliminary design activities.

Verification and Validation Process for Progressive Damage and Failure Analysis Methods in the NASA Advanced Composites Consortium

The Advanced Composites Consortium is a US Government/Industry partnership supporting technologies to enable timeline and cost reduction in the development of certified composite aerospace structures. A key component of the consortium's approach is the development and validation of improved progressive damage and failure analysis methods for composite structures. These methods will enable increased use of simulations in design trade studies and detailed design development, and thereby enable more targeted physical test programs to validate designs. To accomplish this goal with confidence, a rigorous verification and validation process was developed. The process was used to evaluate analysis methods and associated implementation requirements to ensure calculation accuracy and to gage predictability for composite failure modes of interest. This paper introduces the verification and validation process developed by the consortium during the Phase I effort of the Advanced Composites Project. Specific structural failure modes of interest are first identified, and a subset of standard composite test articles are proposed to interrogate a progressive damage analysis method's ability to predict each failure mode of interest. Test articles are designed to capture the underlying composite material constitutive response as well as the interaction of failure modes representing typical failure patterns observed in aerospace structures

Three-dimensional finite element formulations for thick and thin laminated plates

Aiming at satisfying the need for modeling the effects of transverse shear and transverse normal stress in thin and thick laminated plates, a family of three quadrilateral displacement finite elements are formulated. The family includes: a 16 node, 40 degree-of-freedom; a 16 node, 48 degree-of-freedom; and a 24 node, 64 degree-of-freeedom quadrilateral element for modeling each layer of the laminate. To evaluate the formulation and applicability the present elements are used to model a range of example problems of thin and thick laminated plates in bending and stretching, and the results are compared with alternative solutions. Examples show that these three types of finite elements are capable of modeling, to various degrees, the effects of transverse shear and interlaminar stresses which can cause delamination

Benchmarking Mixed Mode Failure in Progressive Damage and Failure Analysis Methods

The verification and validation of progressive-damage-analysis finite element methods are difficult but critical tasks to undertake during their development. Verification exercises assess whether a predictive analysis tool produces results that are consistent with the fundamental concepts and assumptions of the tool under evaluation. Ideally, closed-form analytical solutions can be derived for which method verification results can be compared. Problems selected for computational tool verification are often simple and isolate individual features of the tool. In the case of progressive damage finite element methods, verifications should be performed to evaluate the ability of the model to predict the initiation of damage and its growth through the finite element mesh under a variety of conditions. Mabson et al. proposed a test case of a unidirectional, fiber-reinforced plate with a center crack subjected to tensile loads to evaluate matrix crack propagation predictions. The problem was modeled using the Abaqus Hashin continuum damage mechanics (CDM) model for fiber-reinforced composites. Different combinations of matrix strengths and element sizes were used in the simulations, and the results were compared to a closed-form solution based on linear elastic fracture mechanics (LEFM). It was determined that the Abaqus CDM model could predict the LEFM solution of Mode I cracks only when the finite element mesh density met specific requirements based on the material properties. This paper presents closed-form LEFM solutions for a center notch mixed mode (CNMM) verification problem. Parametric finite element analyses were developed using progressive damage analysis methods of both the Discrete Damage Mechanics (DDM) and CDM classes. The progressive damage analysis methods applied in the analyses of the CNMM problem include CompDam and the Floating Node Method. Analyses were conducted with various mode mixities and element sizes to verify that the damage models were working as intended and to identify any limits of applicability

Progressive damage and failure prediction of open hole tension and open hole compression specimens

Progressive damage and failure in open hole composite laminate coupons under tensile and compressive loading conditions is modeled using Enhanced Schapery Theory (EST). The input parameters required for EST are obtained using standard coupon level test data and are interpreted in conjunction with finite element (FE) based simulations. The ca-pability of EST to perform the open hole strength prediction accurately is demonstrated using three different layups of IM7/8552 carbon fiber composite. A homogenized approach uses a single composite shell element to represent the entire laminate in the thickness di-rection and this requires the fiber direction fracture toughness to be modeled as a laminateproperty. The results obtained using the EST method agree quite well with experimental results. © 2015, by Ashith Joseph, Anthony M. Waas, Wooseok Ji, Evan Pineda, Salvatore Liguore and Steven Wanthal