Micro-mechanical finite element analysis of Z-pins under mixed-mode loading

© 2015 Elsevier Ltd. All rights reserved.This paper presents a three-dimensional micro-mechanical finite element (FE) modelling strategy for predicting the mixed-mode response of single Z-pins inserted in a composite laminate. The modelling approach is based upon a versatile ply-level mesh, which takes into account the significant micro-mechanical features of Z-pinned laminates. The effect of post-cure cool down is also considered in the approach. The Z-pin/laminate interface is modelled by cohesive elements and frictional contact. The progressive failure of the Z-pin is simulated considering shear-driven internal splitting, accounted for using cohesive elements, and tensile fibre failure, modelled using the Weibulls criterion. The simulation strategy is calibrated and validated via experimental tests performed on single carbon/BMI Z-pins inserted in quasi-isotropic laminate. The effects of the bonding and friction at the Z-pin/laminate interface and the internal Z-pin splitting are discussed. The primary aim is to develop a robust numerical tool and guidelines for designing Z-pins with optimal bridging behaviour

Lay-up optimisation of fibre–metal laminates panels for maximum impact absorption

This paper introduces a methodology utilising a ply-ply damage Finite Element models with Genetic algorithm optimisation procedure to investigate the effect of lay-up configuration on the impact absorption properties of fibre metal laminates (FMLs). The methodology was carried out in two steps. In the first step, a pseudo-2D model was used to explore the vast design space to identify potential optimised layup-configurations. In the second step, the optimised configurations were studied in full 3 D, with high fidelity simulations, verifying the results obtained from the optimisation process. The design variables used include thickness and material (including fibre orientation) of each ply. The results produced an optimised configuration consisting of a metallic ply on the impacted side followed by a cross-ply composite lay-up. The results also suggest that the first composite ply (second ply of the FML) should be about 3 times thicker than the other plie

Multi-material topology optimization for composite metal aircraft structures

This paper investigates an optimization routine for lightweight composite-metal hybrid aircraft structures. This routine is developed based on two existing topology optimization approaches, Moving Morphable Components (MMC) and level set method updated by a reaction diffusion equation. The proposed method overcomes the weakness of conventional multi-material optimizers by introducing some rules of material distribution, that enhance the manufacturability of the optimal structure. It is achieved by optimizing the main structural frame using uniform-width components first, leaving the joints as void together with the remaining design domain, and following by a conventional topology optimization using single-material level set approach. A commonly used beam model is optimized to demonstrate the key ideas of the proposed routine

Interaction of Z-pins with Multiple Mode II Delaminations in Composite Laminates

The application of Z-pinning is a subject of great interest in the field of through-thickness reinforcement (TTR) of composite laminates. To date, the majority of Z-pin characterisation work has been conducted on fracture coupons containing a single embedded delamination, which is often not representative of real failure of reinforced composite structures in service. In this investigation a test procedure to produce two independent Mode II delaminations was developed to analyse their interaction with a region of Z-pin reinforcement. Initially numerical models were used to optimise the chosen configuration. Experimental results show in detail the response of Z-pins to two independent delaminations. These results highlight the ability of the Z-pins to effectively arrest mode II delaminations at multiple levels through the sample thickness. Additionally they provide a much needed data set for validation and verification of Z-pin numerical modelling tools

Inter-fibre failure of through-thickness reinforced laminates in combined transverse compression and shear load

Extensive studies have been reported on the improvement of through-thickness reinforcement to inter-laminar performance of composite laminates; current understanding on the in-plane performance is relatively limited, although it is also concerned in industrial application. The influence of through-thickness reinforcement (Z-pinning) on the inter-fibre failure in compression of unidirectional laminates was investigated. Both unpinned and Z-pinned laminates were tested at four different off-axis angles, representing different combinations of transverse compression and in-plane shear stress. It was found that the stiffness of Z-pinned laminates decreased significantly in all off-axis angles. The failure strain and strength were reduced in shear dominated failure modes, while improved in the compression dominated failure modes by the presence of the Z-pins. A further investigation on the angle of failure plane was carried out and a comparison with analytical failure models is presented

Numerical simulations of embedded wrinkle defects geometry on the strength knockdown of FRP composites

With the wide adoption of composite materials for a variety of applications, the prediction of their failure remains a challenging prospect. To complicate this scenario, out-of-plane fibre waviness defects, also known as wrinkle defects, are a major type of manufacturing defects that can degrade the mechanical performances of continuous carbon fibre composite panels, especially their compressive strength. In this work, the effects of such defects on square composite specimens are addressed through Finite Element (FE) analysis. A Matlab-Abaqus FE routine is proposed, which is capable of generating a wide variety of composite specimens with several types of embedded wrinkles and a number of controllable parameters. Parametric analyses are then performed to investigate the effects of defects characteristics on the knockdown in compressive strength, and several conclusions are drawn. Results show that is possible to determine the dependence of compressive strength on various wrinkle parameters such as amplitude or angle

Influence of Z-pin embedded length on the interlaminar traction response of multi-directional composite laminates

The work in this paper investigated the performance of composites through-thickness reinforcing Z-pins as a function of their embedded length in pre-preg laminates. Single Z-pins were inserted into multidirectional carbon fibre laminates with increasing thicknesses, corresponding to embedded lengths from 1 mm to 10 mm and tested through a range of mixed mode displacement ratios to investigate their interlaminar bridging traction response. Detailed analysis of the tests revealed a non-linear tangential friction response and its strong dependence on the embedded length of the Z-pin. Using a new power law empirical relationship for the tangential friction force per unit length, a modified Z-pin bridging traction analytical model was proposed, giving good predictions of the full mixed mode bridging mechanics of a CFRP Z-pin in a multidirectional composite laminate of varying thickness. Several characteristics of the model are discussed and their influence on predicting the Z-pin bridging energy response have been analysed

Cohesive element formulation for z-pin delamination bridging in fibre reinforced laminates

Z-pins are an effective method of reinforcing laminated composite materials for resisting the propagation of delamination. In this paper, a novel numerical method combines the classical cohesive finite element (FE) method with a semi-analytical z-pin crack bridging model. Special purpose cohesive elements, in which the generalized traction-displacement characteristics are provided by the semi-analytical model z-pin bridging map, are implemented in macro-scale FE models. This cohesive element offers the flexibility to employ two cohesive laws concurrently for prediction of delamination propagation, for both the pinned and unpinned behaviour. Its efficacy is evaluated by the simulation of double cantilever beam (DCB), mixed-mode bend (MMB), and pure mode II End-Loaded Split (ELS) fracture tests at 2% z-pin areal density. The numerical results in terms of load-deflection predictions agree well with experiments. The different simulations were all performed using a single set of input parameters derived from single z-pin tests with no fitting factors

Suppressing delaminations in composites across a range of loading modes

This study presents two means of achieving high fracture toughness throughout the entire mixed Mode I/II test range, using customised placement of composite and metal Z-pins in hybrid arrays, and novel hybrid metal/composite Z-pins. The study shows that hybrid arrays that contain an equal number of composite and metal Z-pins exhibit a notable increase in the apparent fracture toughness in Mode II compared to 100% composite pins, while maintaining adequate Mode I performance. Hybrid metal/composite Z-pins, which consist of a composite exterior and a metal core have been shown to offer a single Z-pin solution for high fracture toughness under mixed Mode I/II loads without compromising either Mode I or Mode II performance of individual composite or metal Z-pins respectively. The composite exterior of the hybrid Z-pin ensures high resistance to pull-out failure, whilst the metal core guarantees high energy absorption at high mixed mode load angles via plastic deformation