METCAN: The metal matrix composite analyzer

Metal matrix composites (MMC) are the subject of intensive study and are receiving serious consideration for critical structural applications in advanced aerospace systems. MMC structural analysis and design methodologies are studied. Predicting the mechanical and thermal behavior and the structural response of components fabricated from MMC requires the use of a variety of mathematical models. These models relate stresses to applied forces, stress intensities at the tips of cracks to nominal stresses, buckling resistance to applied force, or vibration response to excitation forces. The extensive research in computational mechanics methods for predicting the nonlinear behavior of MMC are described. This research has culminated in the development of the METCAN (METal Matrix Composite ANalyzer) computer code

GENOA-PFA: Progressive Fracture in Composites Simulated Computationally

GENOA-PFA is a commercial version of the Composite Durability Structural Analysis (CODSTRAN) computer program that simulates the progression of damage ultimately leading to fracture in polymer-matrix-composite (PMC) material structures under various loading and environmental conditions. GENOA-PFA offers several capabilities not available in other programs developed for this purpose, making it preferable for use in analyzing the durability and damage tolerance of complex PMC structures in which the fiber reinforcements occur in two- and three-dimensional weaves and braids. GENOA-PFA implements a progressive-fracture methodology based on the idea that a structure fails when flaws that may initially be small (even microscopic) grow and/or coalesce to a critical dimension where the structure no longer has an adequate safety margin to avoid catastrophic global fracture. Damage is considered to progress through five stages: (1) initiation, (2) growth, (3) accumulation (coalescence of propagating flaws), (4) stable propagation (up to the critical dimension), and (5) unstable or very rapid propagation (beyond the critical dimension) to catastrophic failure. The computational simulation of progressive failure involves formal procedures for identifying the five different stages of damage and for relating the amount of damage at each stage to the overall behavior of the deteriorating structure. In GENOA-PFA, mathematical modeling of the composite physical behavior involves an integration of simulations at multiple, hierarchical scales ranging from the macroscopic (lamina, laminate, and structure) to the microscopic (fiber, matrix, and fiber/matrix interface), as shown in the figure. The code includes algorithms to simulate the progression of damage from various source defects, including (1) through-the-thickness cracks and (2) voids with edge, pocket, internal, or mixed-mode delaminations

Finite element substructuring methods for composite mechanics

Finite element substructuring strategies are presented to obtain numerical solutions for three typical problems of interest to the composites community: (1) impact and toughness characterization of composites using Charpy's impact test specimen; (2) free-edge stress analysis of composite laminates; and (3) fracture toughness predictions of composites for individual and combined fracture of modes I, II, and III. The key issue common to these problems is the presence of singular or near singular stress fields. The regions prone to see steep stress gradients are substructured with progressively refined meshes to study the local response simultaneously with the global response. The results from the select examples indicate that finite element substructuring methods are computationally effective for composite singularity mechanics

Design Procedures for Fiber Composite Box Beams

Step-by-step procedures are described which can be used for the preliminary design of fiber composite box beams subjected to combined loadings. These procedures include a collection of approximate closed-form equations so that all the required calculations can be performed using pocket calculators. Included is an illustrated example of a tapered cantilever box beam subjected to combined loads. The box beam is designed to satisfy strength, displacement, buckling, and frequency requirements

Computational simulation of high temperature metal matrix composite behavior

Computational procedures are described to simulate the thermal and mechanical behavior of high temperature metal matrix composite (HT MMC) in the following four broad areas: (1) behavior of HT MMC from micromechanics to laminate; (2) HT MMC structural response for simple and complex structural components; (3) HT MMC microfracture; and (4) tailoring of HT MMC behavior for optimum specific performance. Representative results from each area are presented to illustrate the effectiveness of the computational simulation procedures. Relevant reports are referenced for extended discussion regarding the specific area

Computational simulation methods for composite fracture mechanics

Structural integrity, durability, and damage tolerance of advanced composites are assessed by studying damage initiation at various scales (micro, macro, and global) and accumulation and growth leading to global failure, quantitatively and qualitatively. In addition, various fracture toughness parameters associated with a typical damage and its growth must be determined. Computational structural analysis codes to aid the composite design engineer in performing these tasks were developed. CODSTRAN (COmposite Durability STRuctural ANalysis) is used to qualitatively and quantitatively assess the progressive damage occurring in composite structures due to mechanical and environmental loads. Next, methods are covered that are currently being developed and used at Lewis to predict interlaminar fracture toughness and related parameters of fiber composites given a prescribed damage. The general purpose finite element code MSC/NASTRAN was used to simulate the interlaminar fracture and the associated individual as well as mixed-mode strain energy release rates in fiber composites

Coupled multi-disciplinary composites behavior simulation

The capabilities of the computer code CSTEM (Coupled Structural/Thermal/Electro-Magnetic Analysis) are discussed and demonstrated. CSTEM computationally simulates the coupled response of layered multi-material composite structures subjected to simultaneous thermal, structural, vibration, acoustic, and electromagnetic loads and includes the effect of aggressive environments. The composite material behavior and structural response is determined at its various inherent scales: constituents (fiber/matrix), ply, laminate, and structural component. The thermal and mechanical properties of the constituents are considered to be nonlinearly dependent on various parameters such as temperature and moisture. The acoustic and electromagnetic properties also include dependence on vibration and electromagnetic wave frequencies, respectively. The simulation is based on a three dimensional finite element analysis in conjunction with composite mechanics and with structural tailoring codes, and with acoustic and electromagnetic analysis methods. An aircraft engine composite fan blade is selected as a typical structural component to demonstrate the CSTEM capabilities. Results of various coupled multi-disciplinary heat transfer, structural, vibration, acoustic, and electromagnetic analyses for temperature distribution, stress and displacement response, deformed shape, vibration frequencies, mode shapes, acoustic noise, and electromagnetic reflection from the fan blade are discussed for their coupled effects in hot and humid environments. Collectively, these results demonstrate the effectiveness of the CSTEM code in capturing the coupled effects on the various responses of composite structures subjected to simultaneous multiple real-life loads

Progression of damage and fracture in composites under dynamic loading

A new computational simulation method is presented to evaluate the dynamic aspects of composite structural response and durability that have not been simulated previously. Composite structural behavior under any loading condition, geometry, composite system, laminate configuration, and boundary conditions can now be simulated. Structural degradation, delamination, fracture, and damage propagation are included in the simulation. An angle-plied composite plate structure under normal impact loading is used as an example to demonstrate the versatility of the simulation method

Damage and fracture in composite thin shells

The effect of fiber fracture on the load carrying capability and structural behavior of a composite cylindrical shell under internal pressure is investigated. An integrated computer code is utilized for the simulation of composite structural degradation under loading. Damage initiation, damage growth, fracture progression, and global structural fracture are included in the simulation. Results demonstrate the significance of local damage on the structural durability of pressurized composite cylindrical shells

Structural behavior of composites with progressive fracture

Structural characteristics such as natural frequencies and buckling loads with corresponding mode shapes were investigated during progressive fracture of multilayer, angle-plied polymer matrix composites. A computer program was used to generate the numerical results for overall mechanical response of damaged composites. Variations in structural characteristics as a function of the previously applied loading were studied. Results indicate that most of the overall structural properties were preserved throughout a significant proportion of the ultimate fracture load. For the cases studied, changes in structural behavior began to occur after 70 percent of the ultimate fracture load was applied. However, the individual nature of the structural change was rather varied depending on the laminate configuration, fiber orientation, and the boundary conditions