Investigating the use of compliant webs in the damage-tolerant design of stiffener run-outs

In this work, the use of a compliant web design for improved damage tolerance in stiffener run-outs is investigated. Firstly, a numerical study that incorporates the possibility of debonding and delamination (using VCCT) is used to select a favourable compliant run-out configuration. Then, three different configurations are compared to establish the merits of the compliant design: a baseline configuration, a configuration with optimised tapering and the selected compliant configuration. The performance of these configurations, in terms of strength and damage tolerance, was compared numerically using a parametric finite element analysis. The energy release rates for debonding and delamination, for different crack lengths across the specimen width, were used for this comparison. The three configurations were subsequently manufactured and tested. In order to monitor the failure process, acoustic emission (AE) equipment was used and proved valuable in the detection and analysis of failure. The predicted failure loads, based on the energy release rates, showed good agreement with the experiments, particularly when the distribution of energy release rate across the width of the specimen was taken into account. As predicted numerically, the compliant configuration failed by debonding and showed improved damage tolerance compared to the baseline and tapered stiffener run-outs.

Design of composite stiffener run-outs for damage tolerance

A major concern in stiffener run-out regions, where the stiffener is terminated due to a cut-out, intersecting rib, or some other structural feature which interrupts the load path, is the relatively weak skin–stiffener interface in the absence of mechanical fasteners. More damage tolerant stiffener run-outs are clearly required and these are investigated in this paper. Using a parametric finite element analysis, the run-out region was optimised for stable debonding crack growth. The modified run-out, as well as a baseline configuration, were manufactured and tested. Damage initiation and propagation was investigated in detail using state-of-the-art monitoring equipment including Acoustic Emission and Digital Image Correlation. As expected, the baseline configuration failed catastrophically. The modified run-out showed improved crack-growth stability, but subsequent delamination failure in the stiffener promptly led to catastrophic failure.

Impact damage and repair of composite structures

This paper gives an overview of the work carried out in a GARTEUR (Group for Aeronautical Research and Technology in Europe) program, under the chairmanship of the author, to develop and validate analytical and numerical methods to characterise real impact damage in composite structures, particularly those designed to sustain load in a postbuckled state, and to study the durability of bonded repairs. GARTEUR is an inter-governmental agreement between the seven European countries with the largest direct employment in the Aerospace industry, to mobilise scientific and technical knowledge between the member countries. A number of Action Groups have been launched, since GARTEUR’s inception in the early 1970s, to address specific technical issues of interest to the participating members. The research presented in this paper was performed under Action Group 28 with partners from ONERA, EADS-CCR (France), DLR, AIRBUS-Deutschland, EADS-M (Germany), CIRA (Italy), INTA (Spain), SICOMP, Saab, (Sweden), NLR (The Netherlands), QinetiQ, BAE Systems, Imperial College London and the University of Sheffield (United Kingdom). The Action Group tasks were divided into four Work Elements (WEs): WE1-Prediction and characterisation of impact damage, WE2- Postbuckling with delamination, WE3-Repair and WE4-Fatigue. This paper outlines the main developments and achievements within each Work Element.

Element-Free Galerkin modelling of composite damage

Delamination and matrix cracking are routine damage mechanisms, observed by post-mortem analysis of laminated structures containing geometrical features such as notches or bolts. Current finite element tools cannot explicitly model an intralaminar matrix microcrack, except if the location of the damage is specified a priori. In this work, a meshless technique, the Element-Free Galerkin (EFG) method, is utilized for the first time to simulate delamination (interlaminar) and intralaminar matrix microcracking in composite laminates.

Optimization strategy for minimizing damage in postbuckling stiffened panels

Composite materials are finding increasing use on primary aerostructures to meet demanding performance targets while reducing environmental impact. This paper presents a finite-element-based preliminary optimization methodology for postbuckling stiffened panels, which takes into account damage mechanisms that lead to delamination and subsequent failure by stiffener debonding. A global-local modeling approach is adopted in which the boundary conditions on the local model are extracted directly from the global model. The optimization procedure is based on a genetic algorithm that maximizes damage resistance within the postbuckling regime. This routine is linked to a finite element package and the iterative procedure automated. For a given loading condition, the procedure optimized the stacking sequence of several areas of the panel, leading to an evolved panel that displayed superior damage resistance in comparison with nonoptimized designs.

The behaviour of damage tolerant hat-stiffened composite panels loaded in uniaxial compression

Damage tolerant hat-stiffened thin-skinned composite panels with and without a centrally located circular cutout, under uniaxial compression loading, were investigated experimentally and analytically. These panels incorporated a highly postbuckling design characterised by two integral stiffeners separated by a large skin bay with a high width to skin-thickness ratio. In both configurations, the skin initially buckled into three half-wavelengths and underwent two mode-shape changes; the first a gradual mode change characterised by a central deformation with double curvature and the second a dynamic snap to five half-wavelengths. The use of standard path-following non-linear finite element analysis did not consistently capture the dynamic mode change and an approximate solution for the prediction of mode-changes using a Marguerre-type Rayleigh-Ritz energy method is presented. Shortcomings with both methods of analysis are discussed and improvements suggested. The panels failed catastrophically and their strength was limited by the local buckling strength of the hat stiffeners. (C) 2001 Elsevier Science Ltd. All rights reserved.

Progress in Fracture and Damage Mechanics

This special-topic volume reports on new progress made in the analysis and understanding of fracture and damage mechanics. The Finite Element Method is a well-established analytical tool for theoretical fracture analysis. The development of interface elements which combine aspects of both fracture and damage mechanics has permitted the prediction of both crack initiation and propagation. A number of the papers presented here deal with their use and further development.Substantial progress has also been made in the use of the Boundary Element Method for treating crack problems. The inherent mathematical complexity of this method has resulted in somewhat slower progress than that enjoyed by the Finite Element Method and is still the focus of much research. The volume also presents a number of contributions arising from this field. A topic which is closely related to the study of fracture is structural repair. Although repairs are usually effected after fracture occurs, the structural analyst must still ensure that the repair itself is not prone to cracking or other forms of damage. Two approaches to the study of damage in a repaired structure are described in this special volume. These three aspects, taken together, ensure that even the expert will learn something new from this book.

A multi-fibre multi-layer representative volume element (M2RVE) for prediction of matrix and interfacial damage in composite laminates

Multiscale micro-mechanics theory is extensively used for the prediction of the material response and damage analysis of unidirectional lamina using a representative volume element (RVE). Th is paper presents a RVE-based approach to characterize the materi al response of a multi-fibre cross-ply laminate considering the effect of matrix damage and fibre-matrix interfacial strength. The framework of the homogenization theory for periodic media has been used for the analysis of a 'multi-fibre multi-layer representative volume element' (M2 RVE) representing cross-ply laminate. The non-homogeneous stress-strain fields within the M2RVE are related to the average stresses and strains by using Gauss theorem and the Hill-Mandal strain energy equivalence principle. The interfacial bonding strength affects the in-plane shear stress-strain response significantl y. The material response predicted by M2 RVE is in good agreement with the experimental results available in the literature. The maximum difference between the shear stress predicted using M2 RVE and the experimental results is ~15% for the bonding strength of 30MPa at the strain value of 1.1%