Impact of composite manufacturing constraints on aerospace stiffened panel design

This paper reports on a design study assessing the impact of laminate manufacturing constraints on the structural performance and weight of composite stiffened panels. The study demonstrates that maximizing ply continuity results in weight penalties, while various geometric constraints related to manufacture and repair can be accommodated without significant weight penalties, potentially generating robust flexible designs.

NONLINEAR NUMERICAL MODELLING OF LIGHTENING STRIKE EFFECT ON COMPOSITE PANELS WITH TEMPERATURE DEPENDANT MATERIAL PROPERTIES

Lightning strike is one of the challenges that the aerospace industry is facing in an effort to increase the percentage of composite materials used in aircraft structures. Lightning strike damage is due to high orthotropic electric resistivity of the composite panels, which leads to high thermal loads that cause decomposition of the epoxy and delimitations of the laminates. Yet, experimental testing of lightning strike on aircraft panels is expensive due to the large number of design parameters that can control the inflicted damage. A coupled thermal-electrical finite element analysis is used to investigate the design variables space that can affect lightning strike damage on epoxy/graphite composite panels. The contribution of this study is modeling the composite panels’ material properties as temperature dependent, which was excluded by other researchers. A number of practical solutions to minimize the damage effect are proposed. Two set of experimental results are used to verify the numerical ones. One experimental set for plain composite panel, and second one for composite panels with joints

Impact of composite ply continuity constraints on aerospace stiffened panel design

Considering the development of aerospace composite components, designing for reduced manufacturing layup cost and structural complexity is increasingly important. While the advantage of composite materials is the ability to tailor designs to various structural loads for minimum mass, the challenge is obtaining a design that is manufacturable and minimizes local ply incompatibility. The focus of the presented research is understanding how the relationships between mass, manufacturability and design complexity, under realistic loads and design requirements, can be affected by enforcing ply continuity in the design process. Presented are a series of sizing case studies on an upper wing cover, designed using conventional analyses and the tabular laminate design process. Introducing skin ply continuity constraints can generate skin designs with minimal ply discontinuities, fewer ply drops and larger ply areas than designs not constrained for continuity. However, the reduced design freedom associated with the addition of these constraints results in a weight penalty over the total wing cover. Perhaps more interestingly, when considering manual hand layup the reduced design complexity is not translated into a reduced recurring manufacturing cost. In contrast, heavier wing cover designs appear to take more time to layup regardless of the laminate design complexity. © 2012 AIAA.

Predicting the crushing behaviour of composite material using high-fidelity finite element modelling

The capability to numerically model the crushing behaviour of composite structures will enable the efficient design of structures with high specific energy absorption capacity. This is particularly relevant to the aerospace and automotive industries where cabin structures need to be shown to be crashworthy. In this paper, a three-dimensional damage model is presented, which accurately represents the behaviour of composite laminates under crush loading. Both intralaminar and interlaminar failure mechanisms are taken into account. The crush damage model was implemented in ABAQUS/Explicit as a VUMAT subroutine. Numerical predictions are shown to agree well with experimental results, accurately capturing the intralaminar and interlaminar damage for a range of stacking sequences, triggers and composite materials. The use of measured material parameters required by the numerical models, without the need to ‘calibrate’ this input data, demonstrates this computational tool's predictive capabilities

Micromechanical Modelling of Non-Homogenous Materials by Meshless Methods

A detailed study of bi-material composites, using meshless methods (MMs), is presented in this paper. Firstly, representative volume elements (RVEs) for different bi-material combinations are analysed by the element-free Galerkin (EFG) method in order to confirm the effective properties of heterogeneous material through homogenization. The results are shown to be in good agreement with experimental results and those obtained using the finite element method (FEM) which required a higher node density. Secondly, a functionally graded material (FGM), with a crack, is analysed using the EFG method. This investigation was motivated by the possibility of replacing the distinct fibrematrix interface with a FGM interface. Finally, an illustrative example showing crack propagation, in a two-dimension micro-scale model of a SiC/Al composite is presented. 

Comparison of Composite Placement Techniques by Recently Qualified Dental Practitioners.

Objectives: To evaluate the placement of composite materials by new graduates using three alternative placement techniques.Methods: A cohort of 34 recently qualified graduates were asked to restore class II interproximal cavities in plastic teeth using three different techniques.

(i) A conventional incremental filling technique (Herculite XRV) using increments no larger than 2-mm with an initial layer on the cervical floor of the box of 1-mm.
(ii) Flowable bulk fill technique (Dentsply SDR) bulk fill placement in a 3-mm layer followed by an incremental fill of a microhybrid resin
(iii) Bulk fill (Kerr Sonicfill) which involved restorations placed in a 5-mm layer.

The operators were instructed in each technique, didactically and with a hands-on demonstration, prior to restoration placement.
All restorations were cured according to manufacturer’s recommendations. Each participant restored 3 teeth, 1 tooth per treatment technique.
The restorations were evaluated using modified USPHS criteria to assess both the marginal adaptation and the surface texture of the restorations. Blind evaluations were carried out independently by two examiners with the aid of magnification (loupes X2.5). Examiners were standardized prior to evaluation.
Results: Gaps between the tooth margins and the restoration or between the layers of the restoration were found in 13 of Group (i), 3 of Group (ii), and 4 of Group (iii)
Statistical analysis revealed a significant difference between the incrementally filled group (i) and the flowable bulk-fill group (ii) (p=0.0043) and between the incrementally filled (i) and the bulk fill groups (iii) (p=0.012) and no statistical difference (p=0.69) between the bulk filled groups Conclusions: Bulk fill techniques may result in a more satisfactory seal of the cavity margins when restoring with composite.

Experimental and numerical study of debonding in composite adhesive joints

The mode I and mode II fracture properties of the FM300-2 adhesive bond between 5HS/RTM6 laminates are determined experimentally by DCB and ELS test. The crack propagation is studied numerically by means of interface elements based on the decohesive zone model. The latter is characterized by material degradation, which is usually assumed to be linear. In the present study it is shown that if a non-linear material degradation is used with an increased magnitude of the interface relative displacement at failure it is possible to model more correctly the experimentally observed significant non-linear behaviour before the start of crack propagation. An adhesive stepped flush joint is studied experimentally and numerically. A mixed mode interaction criterion is used together with the nonlinear material degradation of the interface. Sensitivity studies are performed to study the influence of the parameters defining it.

Numerical analysis of complex failure mechanisms in composite panels

A three-dimensional continuum damage mechanics-based material model has been implemented in an implicit Finite Element code to simulate the progressive degradation of advanced composite materials. The damage model uses seven damage variables assigned to tensile, compressive and non-linear shear damage at a laminae level. The objectivity of the numerical discretization is assured using a smeared formulation. The material model was benchmarked against experimental uniaxial coupon tests and it is shown to reproduce key aspects observable during failure, such as the inclined fracture plane in matrix compression and the shear band in a ±45° tension specimen.