A new mixed model based on the enhanced-Refined Zigzag Theory for the analysis of thick multilayered composite plates

The Refined Zigzag Theory (RZT) has been widely used in the numerical analysis of multilayered and sandwich plates in the last decay. It has been demonstrated its high accuracy in predicting global quantities, such as maximum displacement, frequencies and buckling loads, and local quantities such as through-the-thickness distribution of displacements and in-plane stresses [1,2]. Moreover, the C0 continuity conditions make this theory appealing to finite element formulations [3]. The standard RZT, due to the derivation of the zigzag functions, cannot be used to investigate the structural behaviour of angle-ply laminated plates. This drawback has been recently solved by introducing a new set of generalized zigzag functions that allow the coupling effect between the local contribution of the zigzag displacements [4]. The newly developed theory has been named enhanced Refined Zigzag Theory (en- RZT) and has been demonstrated to be very accurate in the prediction of displacements, frequencies, buckling loads and stresses. The predictive capabilities of standard RZT for transverse shear stress distributions can be improved using the Reissner’s Mixed Variational Theorem (RMVT). In the mixed RZT, named RZT(m) [5], the assumed transverse shear stresses are derived from the integration of local three-dimensional equilibrium equations. Following the variational statement described by Auricchio and Sacco [6], the purpose of this work is to implement a mixed variational formulation for the en-RZT, in order to improve the accuracy of the predicted transverse stress distributions. The assumed kinematic field is cubic for the in-plane displacements and parabolic for the transverse one. Using an appropriate procedure enforcing the transverse shear stresses null on both the top and bottom surface, a new set of enhanced piecewise cubic zigzag functions are obtained. The transverse normal stress is assumed as a smeared cubic function along the laminate thickness. The assumed transverse shear stresses profile is derived from the integration of local three-dimensional equilibrium equations. The variational functional is the sum of three contributions: (1) one related to the membrane-bending deformation with a full displacement formulation, (2) the Hellinger-Reissner functional for the transverse normal and shear terms and (3) a penalty functional adopted to enforce the compatibility between the strains coming from the displacement field and new “strain” independent variables. The entire formulation is developed and the governing equations are derived for cases with existing analytical solutions. Finally, to assess the proposed model’s predictive capabilities, results are compared with an exact three-dimensional solution, when available, or high-fidelity finite elements 3D models. References: [1] Tessler A, Di Sciuva M, Gherlone M. Refined Zigzag Theory for Laminated Composite and Sandwich Plates. NASA/TP- 2009-215561 2009:1–53. [2] Iurlaro L, Gherlone M, Di Sciuva M, Tessler A. Assessment of the Refined Zigzag Theory for bending, vibration, and buckling of sandwich plates: a comparative study of different theories. Composite Structures 2013;106:777–92. https://doi.org/10.1016/j.compstruct.2013.07.019. [3] Di Sciuva M, Gherlone M, Iurlaro L, Tessler A. A class of higher-order C0 composite and sandwich beam elements based on the Refined Zigzag Theory. Composite Structures 2015;132:784–803. https://doi.org/10.1016/j.compstruct.2015.06.071. [4] Sorrenti M, Di Sciuva M. An enhancement of the warping shear functions of Refined Zigzag Theory. Journal of Applied Mechanics 2021;88:7. https://doi.org/10.1115/1.4050908. [5] Iurlaro L, Gherlone M, Di Sciuva M, Tessler A. A Multi-scale Refined Zigzag Theory for Multilayered Composite and Sandwich Plates with Improved Transverse Shear Stresses, Ibiza, Spain: 2013. [6] Auricchio F, Sacco E. Refined First-Order Shear Deformation Theory Models for Composite Laminates. J Appl Mech 2003;70:381–90. https://doi.org/10.1115/1.1572901

Delamination and skin-spar debond detection in composite structures using the inverse Finite Element Method

This work presents a novel strategy for detecting and localizing intra- or inter-laminar damages in composite structures using surface-instrumented strain sensors. It is based on the real-time reconstruction of structural displacements using the inverse Finite Element Method (iFEM). The iFEM reconstructed displacements or strains are post-processed or 'smoothed' to establish a real-time healthy structural baseline. As damage diagnosis is based on comparing damaged and healthy data obtained using the iFEM, no prior data or information regarding the healthy state of the structure is required. The approach is applied numerically on two carbon fiber-reinforced epoxy composite structures: for delamination detection in a thin plate, and skin-spar debond detection in a wing box. The influence of measurement noise and sensor locations on damage detection is also investigated. The results demonstrate that the proposed approach is reliable and robust but requires strain sensors proximal to the damage site to ensure accurate predictions

Shape Sensing for an UAV Composite Half-Wing: Numerical Comparison between Modal Method and Ko’s Displacement Theory

Shape sensing is the reconstruction of the displacement field of a structure from some discrete surface strain measurements and is a key technology for structural health monitoring. Aim of this paper is to compare two approaches to shape sensing that have been shown to be more efficient, especially for aircraft structures applications, in terms of required input strain measurements, the Ko’s Displacement Theory and the Modal Method. Object of the shape-sensing analysis is the half-wing of a multirotor UAV. The approaches are summarized in order to set the framework for the numerical comparative in-vestigation. Then, the multirotor UAV is presented and a finite element model of its half-wing is used to simulate the static response to straight-and-level flight conditions. For a given common set of surface strain measurement points, Ko’s Displacement Theory and the Modal Method are compared in terms of accuracy of the reconstructed half-wing deflection and twist angle. The Modal Method is shown to be more accurate than Ko’s Displacement Theory, especially for the evaluation of the deflection field. Further numerical analyses show that the Modal Method is in-fluenced by the set of mode shapes included in the analysis and that excellent reconstructed de-flections can be obtained with a reduced number of sensors, thus assessing the approach as an ef-ficient shape-sensing tool for aircraft structures real applications

Experimental Shape Sensing and Load Identification on a Stiffened Panel: A Comparative Study

The monitoring of loads and displacements during service life is proving to be crucial for developing a modern Structural Health Monitoring framework. The continuous monitoring of these physical quantities can provide fundamental information on the actual health status of the structure and can accurately guide pro-active condition-based maintenance operations, thus reducing the maintenance costs and extending the service life of the monitored structures. Pushed by these needs and by the simultaneous development in the field of strain sensing technologies, several displacement reconstruction and load identification methods have been developed that are based on discrete strain measurements. Among the different formulations, the inverse Finite Element Method (iFEM), the Modal Method (MM) and the 2-step method, the latter being the only one able to also compute the loads together with the displacements, have emerged as the most accurate and reliable ones. In this paper, the formulation of the three methods is summarized in order to set the numerical framework for a comparative study. The three methods are tested on the reconstruction of the external load and of the displacement field of a stiffened aluminium plate starting from experimentally measured strains. A fibre optic sensing system has been used to measure surface strains and an optimization procedure has been performed to provide the best fibre pattern, based on five lines running along the stiffeners’ direction and with a back-to-back measuring scheme. Additional sensors are used to measure the applied force and the plate’s deflection in some locations. The comparison of the results obtained by each method proves the extreme accuracy and reliability of the iFEM in the reconstruction of the deformed shape of the panel. On the other hand, the Modal Method leads to a good reconstruction of the displacements, but also exhibits a sensitivity to the choice of the modes considered for the specific application. Finally, the 2-step approach is able to correctly identify the loads and to reconstruct the displacements with an accuracy that depends on the modeling of the experimental setup

A homogeneous limit methodology and refinements of computationally efficient zigzag theory for homogeneous, laminated composite, and sandwich plates

The Refined Zigzag Theory (RZT) for homogeneous, laminated composite, and sandwich plates is revisited to offer a fresh insight into its fundamental assumptions and practical possibilities. The theory is introduced from a multiscale formalism starting with the inplane displacement field expressed as a superposition of coarse and fine contributions. The coarse displacement field is that of first-order shear-deformation theory, whereas the fine displacement field has a piecewise-linear zigzag distribution through the thickness. The resulting kinematic field provides a more realistic representation of the deformation states of transverse-shear-flexible plates than other similar theories. The condition of limiting homogeneity of transverse-shear properties is proposed and yields four distinct variants of zigzag functions. Analytic solutions for highly heterogeneous sandwich plates undergoing elastostatic deformations are used to identify the best-performing zigzag functions. Unlike previously used methods, which often result in anomalous conditions and nonphysical solutions, the present theory does not rely on transverse-shear-stress equilibrium constraints. For all material systems, there are no requirements for use of transverse-shear correction factors to yield accurate results. To model homogeneous plates with the full power of zigzag kinematics, infinitesimally small perturbations in the transverse shear properties are derived, thus enabling highly accurate predictions of homogeneous-plate behavior without the use of shear correction factors. The RZT predictive capabilities to model highly heterogeneous sandwich plates are critically assessed, demonstrating its superior efficiency, accuracy, and a wide range of applicability. This theory, which is derived from the virtual work principle, is well-suited for developing computationally efficient, C0 a continuous function of (x1,x2) coordinates whose first-order derivatives are discontinuous along finite element interfaces and is thus appropriate for the analysis and design of high-performance load-bearing aerospace structures

Refinement of Timoshenko Beam Theory for Composite and Sandwich Beams Using Zigzag Kinematics

A new refined theory for laminated-composite and sandwich beams that contains the kinematics of the Timoshenko Beam Theory as a proper baseline subset is presented. This variationally consistent theory is derived from the virtual work principle and employs a novel piecewise linear zigzag function that provides a more realistic representation of the deformation states of transverse shear flexible beams than other similar theories. This new zigzag function is unique in that it vanishes at the top and bottom bounding surfaces of a beam. The formulation does not enforce continuity of the transverse shear stress across the beam s cross-section, yet is robust. Two major shortcomings that are inherent in the previous zigzag theories, shear-force inconsistency and difficulties in simulating clamped boundary conditions, and that have greatly limited the utility of these previous theories are discussed in detail. An approach that has successfully resolved these shortcomings is presented herein. This new theory can be readily extended to plate and shell structures, and should be useful for obtaining accurate estimates of structural response of laminated composites

Nonlinear static response analysis of sandwich beams using the Refined Zigzag Theory

The Refined Zigzag Theory (RZT) is assessed for the buckling and nonlinear static response analysis of multilayered composite and sandwich beams. A nonlinear formulation of the RZT is developed taking into account geometric imperfections and nonlinearities using the Von Kármán nonlinear strain-displacement relations. FE analyses are conducted employing C0-beam elements based on the RZT and the Timoshenko Beam Theory (TBT) to model three sandwich beams with different core materials and slenderness ratios, in both simply supported and cantilever configurations. The reference solutions are obtained by high-fidelity FE commercial codes, Abaqus® and Nastran®. The first two buckling loads and mode shapes are evaluated for the beams without initial imperfections. Several shapes are then assumed as geometric imperfections to calculate the beams nonlinear response to axial-compressive loads. The comparisons show the very high accuracy of the RZT (comparable to high-fidelity FE commercial codes) for both the buckling and nonlinear static analyses and its superior capability with respect to the TBT to deal with sandwich beams with low slenderness ratio and higher face-to-core stiffness ratio

A Refined Zigzag Beam Theory for Composite and Sandwich Beams

A new refined theory for laminated composite and sandwich beams that contains the kinematics of the Timoshenko Beam Theory as a proper baseline subset is presented. This variationally consistent theory is derived from the virtual work principle and employs a novel piecewise linear zigzag function that provides a more realistic representation of the deformation states of transverse-shear flexible beams than other similar theories. This new zigzag function is unique in that it vanishes at the top and bottom bounding surfaces of a beam. The formulation does not enforce continuity of the transverse shear stress across the beam s cross-section, yet is robust. Two major shortcomings that are inherent in the previous zigzag theories, shear-force inconsistency and difficulties in simulating clamped boundary conditions, and that have greatly limited the utility of these previous theories are discussed in detail. An approach that has successfully resolved these shortcomings is presented herein. Exact solutions for simply supported and cantilevered beams subjected to static loads are derived and the improved modelling capability of the new zigzag beam theory is demonstrated. In particular, extensive results for thick beams with highly heterogeneous material lay-ups are discussed and compared with corresponding results obtained from elasticity solutions, two other zigzag theories, and high-fidelity finite element analyses. Comparisons with the baseline Timoshenko Beam Theory are also presented. The comparisons clearly show the improved accuracy of the new, refined zigzag theory presented herein over similar existing theories. This new theory can be readily extended to plate and shell structures, and should be useful for obtaining relatively low-cost, accurate estimates of structural response needed to design an important class of high-performance aerospace structures

A novel algorithm for shape parameter selection in radial basis functions collocation method

Many Radial Basis Functions (RBF) contain a free shape parameter that plays an important role for the application of meshless method to the analysis of multilayered composite and sandwich plates. In most papers the authors end up choosing this shape parameter by trial and error or some other ad-hoc means. In this paper a novel algorithm for shape parameter selection, based on a convergence analysis, is presented. The effectiveness of this algorithm is assessed by static analyses of laminated composite and sandwich plate

Refined Zigzag Theory for Homogeneous, Laminated Composite, and Sandwich Plates: A Homogeneous Limit Methodology for Zigzag Function Selection

The Refined Zigzag Theory (RZT) for homogeneous, laminated composite, and sandwich plates is presented from a multi-scale formalism starting with the inplane displacement field expressed as a superposition of coarse and fine contributions. The coarse kinematic field is that of first-order shear-deformation theory, whereas the fine kinematic field has a piecewise-linear zigzag distribution through the thickness. The condition of limiting homogeneity of transverse-shear properties is proposed and yields four distinct sets of zigzag functions. By examining elastostatic solutions for highly heterogeneous sandwich plates, the best-performing zigzag functions are identified. The RZT predictive capabilities to model homogeneous and highly heterogeneous sandwich plates are critically assessed, demonstrating its superior efficiency, accuracy ; and a wide range of applicability. The present theory, which is derived from the virtual work principle, is well-suited for developing computationally efficient CO-continuous finite elements, and is thus appropriate for the analysis and design of high-performance load-bearing aerospace structures