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The Joint Advanced Materials and Structures Center of Excellence
Industry Participation
-Raytheon Missile Systems
The Joint Advanced Materials and Structures Center of Excellence
Objective
To investigate the damage tolerance and durability of bidirectionally reinforced GLARE laminates. Such information will
be used to support the airworthiness certification and property
optimization of GLARE structures
Approach
To develop analytical methods validated by experiments
To develop information system
The Joint Advanced Materials and Structures Center of Excellence
Background
GLARE (S2-glass fiber reinforced Al) laminates
Hybrid composites consisting of alternating thin metal
layers and glass fibers
Advantages of GLARE
High specific properties and low density
Outstanding fatigue resistance
Excellent impact resistance and
damage tolerance
Good corrosion and durability
Easy inspection like aluminum structures
Excellent flame resistance
The Joint Advanced Materials and Structures Center of Excellence
Project Scope
To develop methodologies for guiding material development, property
optimization and airworthiness certification:
Delamination front-fiber/adhesive
11
12
13
14
15
180000
1T-120 MPa
2T-120 MPa
3T-120 MPa
4T-120 MPa
1T-100 MPa
2T-100 MPa
3T-100 MPa
4T-100 MPa
160000
140000
N (cycle)
120000
100000
80000
60000
40000
20000
0
-30
-25
-20
-15
-10
-5
10
15
20
25
30
a (mm)
16
180000
1B-120 MPa
2B-120 MPa
3B-120 MPa
4B-120 MPa
1B-100 MPa
2B-100 MPa
3B-100 MPa
4B-100 MPa
160000
140000
N (cycle)
120000
100000
80000
60000
40000
20000
0
-30
-20
-10
10
20
30
a (mm)
17
0.01
da/dN (mm/cycle)
1E-3
1E-4
3T-120 MPa
4T-120 MPa
3T-100 MPa
4T-100 MPa
1E-5
1E-6
5
10
15
20
25
a (mm)
18
da
= C g ( K eff
dN
ng
K eff = ( K re K op )(1 ), =K br / K re
19
260
240
220
200
180
160
140
120
100
80
60
40
20
0
-20
-40
-60
-80
-100
0.00
applied stress
stress in Al
curing stress in Al
curing stress in 0 ply
curing stress in 90 ply
0.05
0.10
0.15
0.20
0.25
0.30
0.35
Time (sec)
Po-Yu Chang, Jenn-Ming Yang, et al. (2007) Off-axis fatigue cracking behavior of notched
fiberand
metalStructures
laminates, Fatigue
Fractof
Eng
Mater Struct.30:158-1171
The Joint Advanced Materials
Center
Excellence
20
21
1/ 2
f2h f A f w
K B = ( a2 )
f h f B fl
K C = ( a3 )
f2h f A f w
1/ 2
1/ 2
1/2
K A = ( a1 )
Kfar (MPa m )
interaction
non-interaction
20
10
-40
-30
-20
-10
10
20
30
40
a (mm)
22
u fml , Al = u ( x) ubr ( x)
u fml , Al = f ( x) + pp ( x) + Al
Guo YJ, Wu XR. (1999) Bridging stress distribution in center-cracked fiber reinforced metal
laminates: modelling and experiment. Eng Fract Mech; 63:14763.
23
Governing equation
br = M j 1 N
N = u ( x) pp ( x)
Mj =
f
Ef
ubr ( xi , x j )x j
br ( x j )
b( x )
b( xi )
(i, j )
Ef
24
140
120 MPa
80 MPa
120
100
80
60
40
20
0
-25
-20
-15
-10
-5
10
15
20
25
a (mm)
25
K br , j =
j =i
2 br' , Al , j x j
tan(
(sin
a
s
a
s
) cos(
xj
) 2 (sin
xj
s
)2
26
Bridging factors
27
Kre
kbr
Keff
50
1/2
K (MPa m )
40
30
20
10
0
0
10
20
30
40
a (mm)
28
0.01
da/dN (mm/cycle)
1E-3
1E-4
3T-120 MPa
4T-120 MPa
3T-100 MPa
4T-100 MPa
1E-5
1E-6
5
10
15
20
25
a (mm)
29
0.01
exp,120 MPa
exp,100 MPa
pre,120 MPa
pre,100 MPa
da/dN (mm/cycle)
1E-3
1E-4
1E-5
1E-6
0
10
15
a (mm)
30
31
Conclusion
The crack growth behavior of a fiber metal laminate with multiple site
damage has been investigated experimentally and analytically.
When the fatigue cracks emanated from the open holes and
propagated, the crack growth rate was faster with the presence of
MSD cracks as compared to the case without the presence of MSD
cracks.
32
33
Boundary Conditions:
Rigid Impactor
Model Geometry:
Data Measurement:
As a consequence of the planar assumption, required by most commercial finite element programs,
non-linear behavior of the material can be significantly underestimated if the out-of-plane components
are non-trivial.
f ft
1
= in11it + in it
12
11 +
= in11
1
it
2
12
+ 132 ) 1
11
f mt =
f mc
in it 2
22 +
( 22 + 33 )
in it 2
12
2
23
+ 122 + 132 22 33 ) 1
2
in it
1 22
1
1
= in it
( 22 + 33 ) + init
in it
22 2 12
12
2
2
22
+ 33
2
2
2
+
+
23
12
13 1
35
EnL
t = min min d
i =1,3 n =1, nblock v
i
36
( t + t ) 2
w& i ( t + t ) = 0 + 1wi (t ) threshold 1 where i are constants
Where the threshold required to produce damage is assumed to decrease with increasing
damage density. In other words, cracking is easier if more cracks are present
ithreshold = iinit (1 wi ( t ) )
Since the individual step time is small, we assume a linear form for the degradation rate
w& i ( t + t )
wi ( t + t ) wi (t )
wi ( t + t )
t
wi (t ) + w& i ( t + t ) t
where t << 1
37
Once a failure criteria value exceeds one, it produces a non-zero damage growth rate. The effective
element stress is reduced by adjusting the elastic constants
Degraded Material Properties
Failure Mode
E11
E22
v23
G12
Fiber Tension
Fiber Compression
G23
Matrix Tension
Matrix Compression
E = (1 w ft )(1 w fc ) E11
'
11
v12
E'
' 11
v12
E11'
'
v12
E11'
SD =
0
Where:
v12'
'
11
v12'
E
1
'
v23
'
22
'
E22
'
v23
E11'
'
E22
'
E22
C D = S D1
and
G12'
G12'
'
G23
( t + t ) = C D ( t + t )
38
ABAQUS Explicit
0.1
39
For low energy impact, its clear that the three-dimensional failure criteria model is capable of predicting the
impact response of the material
At this energy, there is no significant difference between the two- and three-dimensional criterion. Both
represent an improvement over a model which does not incorporate failure
This represents a limiting case, in which planar failure mechanisms dominate. Damage to the sample is
negligible, we call it Barely Visible Impact Damage (BVID)
The Joint Advanced Materials and Structures Center of Excellence
40
Cracking on the
non-impacted side
At higher impact energies, it is evident that while the correlation is still good, it begins to break
down due to damage modes
Additionally, the impact period is underestimated because of the perfect clamping assumption
and one-directional constraint on the rigid impactor.
As expected, the peak impact force and peak impact time are better predicted using the threedimensional model. Overall, the three-dimensional model is more conservative than the twodimensional model
The Joint Advanced Materials and Structures Center of Excellence
41
For low energy impact, its clear that the two-dimensional failure criteria model is capable of predicting the
impact response of the material
At this energy, as shown in GLARE 5-2/1 there are plastic deformation only
This represents a limiting case, in which planar failure mechanisms dominate. Damage to the sample is
negligible, we call it Barely Visible Impact Damage (BVID)
The Joint Advanced Materials and Structures Center of Excellence
42
90
90
0
43
Crack propagating
direction
No crack
Dent damage at non-impacted Al layer
1-directional stress at non-impacted Al layer
When we check 1-directional stress at impacted and non-impacted side for crack initiation, tensile stress dominates
impacted Al layer. But at non-impacted Al layer compressive stress dominates. Therefore, when tensile load apply
to 1 direction in fatigue behavior, crack initiate on impacted Al layer only.
44
GLARE 4-3/2 also show crack just initiate on impacted Al layer as shown in GLARE 5-2/1.
45
Investigation of Stress on
Aluminum Layer-GLARE5-2/1
6
7
2
<Von-Misses Stress>
Stress (MPa)
12.7J-impacted
435
313
282
312
436
430
446
12.7J-non-impacted
445
306
309
303
241
206
234
16.3J-impacted
408
347
362
374
432
414
441
16.3J-non-impacted
364
298
296
319
234
219
200
46
Investigation of Stress on
Aluminum Layer-GLARE5-2/1
Tensile loading direction
12.7J-impacted
-456
-234
81
-216
-389
35
-390
12.7J-non-impacted
-449
-268
-231
-261
-281
-57
-287
16.3J-impacted
-481
-293
72
-294
-410
13
-415
16.3J-non-impacted
-445
-292
-298
-284
-285
-56
-271
Impact dent
Crack initiation
Nuisance crack
Impact dent (1): By impact force, compressive stress dominate on impacted and nonimpacted side of aluminum.
The outer impact dent (3)
- Impacted side: Since the fiber layers would be elastically deformed and the outer concave
dent region experience the state of tension.
- Non-impacted side: By elastic deformation of fiber layer, the compressive loading occurred
on non-impacted aluminum layer.
The nuisance crack (5&7): To investigate nuisance cracks, stresses were detected on
region 5 and 7. Impacted and non-impacted of aluminum layers experience compressive
loading. However, these numerical results isnt enough to explain them. Since the nuisance
cracks were exhibited randomly under high tensile fatigue loading level. Therefore, it is
47
Joint
Advanced
Materialsnumerical
and Structures
Center of Excellence
needed to apply The
tensile
loading
to impacted
model.
Boundary Conditions:
Rigid Impactor
Model Geometry:
Impact type:
ABAQUS Explicit
SC8R (shell)
Failure criteria
0.1
0.15
0.15
Out-of-plane displacement
hourglassMaterials
scaling factor
0.15
The Joint Advanced
and Structures Center of Excellence
49
Multiple Impacts were simulated for diverse mesh type like coarse, fine and circle. As seen in above plot,
for impact they arent different.
1st and 2nd impact show plastic deformation and after 2nd impact some vibration was investigated. This
vibration may be from stress wave or damping effect. In a simulation, vibration wasnt shown in FEM
result.
Usually, FEM show lower peak impact force than experimental result. This may be caused by full fixed
boundary condition.
50
The Joint Advanced Materials and Structures Center of Excellence
This FEM result show similar result with impact energy 8J.
The Joint Advanced Materials and Structures Center of Excellence
51
Experiment (kN)
Error (%)
1st
2nd
1st
2nd
1st
2nd
3.23
4.36
2.77
3.93
14
9.9
16
4.66
6.47
3.87
5.36
17
17
20
5.31
6.97
4.32
5.77
19
17
Experiment (mm)
1st
2nd
Total
1st
2nd
Total
2.48
1.76
4.24
2.56
1.46
4.02
5.2
16
3.34
2.12
5.46
3.60
1.90
5.5
0.7
20
3.72
2.47
6.19
4.07
1.97
6.04
2.4
Error (%)
52
53
54
Summary
55
A Look Forward
Benefit to Aviation
--Development of analytical models validated
by experiment and the information system
are critical to design optimization and to
support the airworthiness certification.
Future needs
--Post-impact fatigue behavior for multiple
impacts
--New generation of fiber metal laminates
The Joint Advanced Materials and Structures Center of Excellence
56