Numerical prediction of the low-velocity impact damage and compression after impact strength of composite laminates

Low-velocity impact damage can drastically reduce the residual mechanical properties of the composite structure even when there is barely visible impact damage. The ability to computationally predict the extent of damage and compression after impact (CAI) strength of a composite structure can potentially lead to the exploration of a larger design space without incurring significant development time and cost penalties. A three-dimensional damage model, to predict both low-velocity impact damage and compression after impact CAI strength of composite laminates, has been developed and implemented as a user material subroutine in the commercial finite element package, ABAQUS/Explicit. The virtual tests were executed in two steps, one to capture the impact damage and the other to predict the CAI strength. The observed intra-laminar damage features, delamination damage area as well as residual strength are discussed. It is shown that the predicted results for impact damage and CAI strength correlated well with experimental testing.

Measuring and modelling air mass flow rate in the injection stretch blow moulding process

The injection stretch blow moulding process involves the inflation and stretching of a hot preform into a mould to form bottles. A critical process variable and an essential input for process simulations is the rate of pressure increase within the preform during forming, which is regulated by an air flow restrictor valve. The paper describes a set of experiments for measuring the air flow rate within an industrial ISBM machine and the subsequent modelling of it with the FEA package ABAQUS. Two rigid containers were inserted into a Sidel SBO1 blow moulding machine and subjected to different supply pressures and air flow restrictor settings. The pressure and air temperature were recorded for each experiment enabling the mass flow rate of air to be determined along with an important machine characteristic known as the ‘dead volume’. The experimental setup was simulated within the commercial FEA package ABAQUS/Explicit using a combination of structural, fluid and fluid link elements that idealize the air flowing through an orifice behaving as an ideal gas under isothermal conditions. Results between experiment and simulation are compared and show a good correlation.

Finite element modelling of composite structures under crushing load

This paper details the theory and implementation of a composite damage model, addressing damage within a ply (intralaminar) and delamination (interlaminar), for the simulation of crushing of laminated composite structures. It includes a more accurate determination of the characteristic length to achieve mesh objectivity in capturing intralaminar damage consisting of matrix cracking and fibre failure, a load-history dependent material response, an isotropic hardening nonlinear matrix response, as well as a more physically-based interactive matrix-dominated damage mechanism. The developed damage model requires a set of material parameters obtained from a combination of standard and non-standard material characterisation tests. The fidelity of the model mitigates the need to manipulate, or "calibrate", the input data to achieve good agreement with experimental results. The intralaminar damage model was implemented as a VUMAT subroutine, and used in conjunction with an existing interlaminar damage model, in Abaqus/Explicit. This approach was validated through the simulation of the crushing of a cross-ply composite tube with a tulip-shaped trigger, loaded in uniaxial compression. Despite the complexity of the chosen geometry, excellent correlation was achieved with experimental results.

Predicting low velocity impact damage and Compression-After-Impact (CAI) behaviour of composite laminates

Low-velocity impact damage can drastically reduce the residual strength of a composite structure even when the damage is barely visible. The ability to computationally predict the extent of damage and compression-after-impact (CAI) strength of a composite structure can potentially lead to the exploration of a larger design space without incurring significant time and cost penalties. A high-fidelity three-dimensional composite damage model, to predict both low-velocity impact damage and CAI strength of composite laminates, has been developed and implemented as a user material subroutine in the commercial finite element package, ABAQUS/Explicit. The intralaminar damage model component accounts for physically-based tensile and compressive failure mechanisms, of the fibres and matrix, when subjected to a three-dimensional stress state. Cohesive behaviour was employed to model the interlaminar failure between plies with a bi-linear traction–separation law for capturing damage onset and subsequent damage evolution. The virtual tests, set up in ABAQUS/Explicit, were executed in three steps, one to capture the impact damage, the second to stabilize the specimen by imposing new boundary conditions required for compression testing, and the third to predict the CAI strength. The observed intralaminar damage features, delamination damage area as well as residual strength are discussed. It is shown that the predicted results for impact damage and CAI strength correlated well with experimental testing without the need of model calibration which is often required with other damage models.

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

Numerical prediction of the low-velocity impact damage and compression after impact strength of composite laminates

Low-velocity impact damage can drastically reduce the residual mechanical properties of the composite structure even when there is barely visible impact damage. The ability to computationally predict the extent of damage and compression after impact (CAI) strength of a composite structure can potentially lead to the exploration of a larger design space without incurring significant development time and cost penalties. A three-dimensional damage model, to predict both low-velocity impact damage and compression after impact CAI strength of composite laminates, has been developed and implemented as a user material subroutine in the commercial finite element package, ABAQUS/Explicit. The virtual tests were executed in two steps, one to capture the impact damage and the other to predict the CAI strength. The observed intra-laminar damage features, delamination damage area as well as residual strength are discussed. It is shown that the predicted results for impact damage and CAI strength correlated well with experimental testing.

Concrete damage plasticity model for modeling FRP-to-concrete bond behavior

The technique of externally bonding fiber-reinforced polymer (FRP) composites has become very popular worldwide for retrofitting existing reinforced concrete (RC) structures. Debonding of FRP from the concrete substrate is a typical failure mode in such strengthened structures. The bond behavior between FRP and concrete thus plays a crucial role in these structures. The FRP-to-concrete bond behavior has been extensively investigated experimentally, commonly using a single or double shear test of the FRP-to-concrete bonded joint. Comparatively, much less research has been concerned with numerical simulation, chiefly due to difficulties in the accurate modeling of the complex behavior of concrete. This paper presents a simple but robust finite-element (FE) model for simulating the bond behavior in the entire debonding process for the single shear test. A concrete damage plasticity model is proposed to capture the concrete-to-FRP bond behavior. Numerical results are in close agreement with test data, validating the model. In addition to accuracy, the model has two further advantages: it only requires the basic material parameters (i.e., no arbitrary user-defined parameter such as the shear retention factor is required) and it can be directly implemented in the FE software ABAQUS.

Finite Element Analysis of the Enhanced Strength of Laterally Restrained RC Slabs

This paper presents the numerical simulation of the ultimate behaviour of 85 one-way and two-way spanning laterally restrained concrete slabs of variable thickness, span, reinforcement ratio, strength and boundary conditions reported in literature by different authors. The developed numerical model was described and all the assumptions were illustrated. ABAQUS, a Finite Element Analysis suite of software, was employed. Non-linear implicit static general analysis method offered by ABAQUS was used. Other analysis methods were also discussed in general in terms of application such as Explicit Dynamic Analysis and Riks method. The aim is to demonstrate the ability and efficacy of FEA to simulate the ultimate load behaviour of slabs considering different material properties and boundary conditions. The authors intended to present a numerical model that provides consistent predictions of the ultimate behaviour of laterally restrained slabs that could be used as an alternative for expensive real life testing as well as for the design and assessment of new and existing structures respectively. The enhanced strength of laterally-restrained slabs compared with conventional design methods predictions is believed to be due to compressive membrane action (CMA). CMA is an inherent phenomenon of laterally restrained concrete beams/slabs. The numerical predictions obtained from the developed model were in good correlation with the experimental results and with those obtained from the CMA method developed at the Queen’s University Belfast, UK.

The effect of manufacture and assembly joining methods on stiffened panel performance

This paper describes the simulation of representative aircraft wing stiffened panels under axial compression loading, to determine the effects of varying the manufacturing shape and assembly joining methods on stiffened panel performance. T-stiffened and Z-stiffened panels are modelled in Abaqus simulating integral, co-cured and mechanically fastened joints. The panels are subject to an edge compressive displacement along the stiffener axis until failure and the ultimate failure load and buckling performance is assessed for each. Integral panels consistently offer the highest performance. Co-cured panels demonstrate reduced performance (3-5% reduction in ultimate load relative to integral) caused by localised cohesive failure and skin-stiffener separation. The mechanically fastened panels are consistently the weakest joint (19-25% reduction in ultimate load relative to integral) caused primarily by inter-rivet buckling between fasteners

Improving composite damage modelling through automatic placement of cohesive elements

Numerous experimental studies of damage in composite laminates have shown that intralaminar (in-plane) matrix cracks lead to interlaminar delamination (out-of-plane) at ply interfaces. The smearing of in-plane cracks over a volume, as a consequence of the use of continuum damage mechanics, does not always effectively capture the full extent of the interaction between the two failure mechanisms. A more accurate representation is obtained by adopting a discrete crack approach via the use of cohesive elements, for both in-plane and out-of-plane damage. The difficulty with cohesive elements is that their location must be determined a priori in order to generate the model; while ideally the position of the crack migration, and more generally the propagation path, should be obtained as part of the problem’s solution. With the aim of enhancing current modelling capabilities with truly predictive capabilities, a concept of automatic insertion of interface elements is utilized. The consideration of a simple traction criterion in relation to material strength, evaluated at each node of the model (or of the regions of the model where it is estimated cracks might form), allows for the determination of initial crack location and subsequent propagation by the insertion of cohesive elements during the course of the analysis. Several experimental results are modelled using the commercial package ABAQUS/Standard with an automatic insertion subroutine developed in this work, and the results are presented to demonstrate the capabilities of this technique.

3D FEM simulation of helical milling hole process for titanium alloy Ti-6Al-4V

As an emerging hole-machining methodology, helical milling process has become increasingly popular in aeromaterials manufacturing research, especially in areas of aircraft structural parts, dies, and molds manufacturing. Helical milling process is highly demanding due to its complex tool geometry and the progressive material failure on the workpiece. This paper outlines the development of a 3D finite element model for helical milling hole of titanium alloy Ti-6Al-4V using commercial FE code ABAQUS/Explicit. The proposed model simulates the helical milling hole process by taking into account the damage initiation and evolution in the workpiece material. A contact model at the interface between end-mill bit and workpiece has been established and the process parameters specified. Furthermore, a simulation procedure is proposed to simulate different cutting processes with the same failure parameters. With this finite element model, a series of FEAs for machined titanium alloy have been carried out and results compared with laboratory experimental data. The effects of machining parameters on helical milling have been elucidated, and the capability and advantage of FE simulation on helical milling process have been well presented.

Finite element modelling of cyclic behaviour of cold-formed steel bolted moment-resisting connections

This paper investigates the accuracy of new finite element modelling approaches to predict the behaviour of bolted moment-connections between cold-formed steel members, formed by using brackets bolted to the webs of the section, under low cycle fatigue. ABAQUS software is used as a modelling platform. Such joints are used for portal frames and potentially have good seismic resisting capabilities, which is important for construction in developing countries. The modelling implications of a two-dimensional beam element model, a three-dimensional shell element model and a three-dimensional solid element model are reported. Quantitative and qualitative results indicate that the three-dimensional quadratic S8R shell element model most accurately predicts the hysteretic behaviour and energy dissipation capacity of the connection when compared to the test results.

Numerical considerations for the implementation of a comprehensive composite damage model

A comprehensive continuum damage mechanics model [1] had been developed to capture the detailed
behaviour of a composite structure under a crushing load. This paper explores some of the difficulties
encountered in the implementation of this model and their mitigation. The use of reduced integration
element and a strain softening model both negatively affect the accuracy and stability of the
simulation. Damage localisation effects demanded an accurate measure of characteristic length. A
robust algorithm for determining the characteristic length was implemented. Testing showed that this
algorithm produced marked improvements over the use of the default characteristic length provided
by Abaqus. Zero-energy or hourglass modes, in reduced integration elements, led to reduced
resistance to bending. This was compounded by the strain softening model, which led to the formation
of elements with little resistance to deformation that could invert if left unchecked. It was shown,
through benchmark testing, that by deleting elements with excess distortions and controlling the mesh
using inbuilt distortion/hourglass controls, these issues can be alleviated. These techniques
contributed significantly to the viability and usability of the damage model.

Development of Seismic Fragility Functions for a Moment Resisting Reinforced Concrete Framed Structure

Understanding the seismic vulnerability of building structures is important for seismic engineers, building owners, risk insurers and governments. Seismic vulnerability defines a buildings predisposition to be damaged as a result of an earthquake of a given severity. There are two components to seismic risk; the seismic hazard and the exposure of the structural inventory to any given earthquake event. This paper demonstrates the development of fragility curves at different damage states using a detailed mechanical model of a moment resisting reinforced concrete structure typical of Southern Europe. The mechanical model consists of a complex three-dimensional finite element model of the reinforced concrete moment resisting frame structure and is used to define the damage states through pushover analysis. Fragility curves are also defined using the HAZUS macroseismic methodology and the Risk-UE macroseismic methodology. Comparison of the mechanically modelled and HAZUS fragility curve shows good agreement while the Risk-UE methodology shows reasonably poor agreement.

Finite Element Simulations of stretch-blow moulding with experimental validation over a broad process window

Injection stretch blow moulding is a well-established method of forming thin-walled containers and has been extensively researched for numerous years. This paper is concerned with validating the finite element analysis of the free-stretch-blow process in an effort to progress the development of injection stretch blow moulding of poly(ethylene terephthalate). Extensive data was obtained experimentally over a wide process window accounting for material temperature and air flow rate, while capturing cavity pressure, stretch-rod reaction force and preform surface strain. This data was then used to assess the accuracy of the correlating FE simulation constructed using ABAQUS/Explicit solver and an appropriate viscoelastic material subroutine. Results reveal that the simulation is able to give good quantitative correlation for conditions where the deformation was predominantly equal biaxial whilst qualitative correlation was achievable when the mode of deformation was predominantly sequential biaxial. Overall the simulation was able to pick up the general trends of how the pressure, reaction force, strain rate and strain vary with the variation in preform temperature and air flow rate. The knowledge gained from these analyses provides insight into the mechanisms of bottle formation, subsequently improving the blow moulding simulation and allowing for reduction in future development costs.