An automated hybrid procedure for capturing mode-jumping in postbuckling composite stiffened structures

This paper presents a robust finite element procedure for modelling the behaviour of postbuckling structures undergoing mode-jumping. Current non-linear implicit finite element solution schemes, found in most finite element codes, are discussed and their shortcomings highlighted. A more effective strategy is presented which combines a quasi-static and a pseudo-transient routine for modelling this behaviour. The switching between these two schemes is fully automated and therefore eliminates the need for user intervention during the solution process. The quasi-static response is modelled using the are-length constraint while the pseudo-transient routine uses a modified explicit dynamic routine, which is more computationally efficient than standard implicit and explicit dynamic schemes. The strategies for switching between the quasi-static and pseudo-transient routines are presented

Efficient modelling and optimisation of hybrid multilayered plates subject to ballistic impact

Among the key challenges present in the modelling and optimisation of composite structures against impact is the computational expense involved in setting up accurate simulations of the impact event and then performing the iterations required to optimise the designs. It is of more interest to find good designs given the limitations of the resources and time available rather than the best possible design. In this paper, low cost but sufficiently accurate finite element (FE) models were generated in LS Dyna for several experimentally characterised materials by semi-automating the modelling process and using existing material models. These models were then used by an optimisation algorithm to generate new hybrid offspring, leading to minimum weight and/or cost designs from a selection of isotropic metals, polymers and orthotropic fibre-reinforced laminates that countered a specified impact threat. Experimental validation of the optimal designs thus identified was then successfully carried out using a single stage gas gun. With sufficient computational hardware, the techniques developed in this pilot study can further utilise fine meshes, equations of state and sophisticated material models, so that optimal hybrid systems can be identified from a wide range of materials, designs and threats.

A study of secondary instabilities in postbuckling composite aerostructures

A number of experimental studies have shown that postbuckling stiffened composite panels, loaded in uniaxial compression, may undergo secondary instabilities, characterised by an abrupt change in the buckled mode-shape of the skin between the supporting stiffeners. In this study high-speed digital speckle photogrammetry is used to gain further insight into an I-stiffened panel's response during this transient phase. This energy-dissipating phenomenon will be shown to be able to cause catastrophic structural failure in vulnerable structures. It is therefore imperative that an accurate and reliable methodology is available to predict this phenomenon. The shortcomings of current non-linear implicit solution schemes, found in most commercially-available finite element codes, are discussed. A robust and efficient strategy, which utilises an automated quasi-, static/pseudo-transient hybrid scheme, is presented in this paper and validated using a number of experimental tests. This approach is shown to be able to predict mode-jumping with good accuracy.

Intralaminar toughness characterisation of unbalanced hybrid plain weave laminates

A numerical and experimental investigation on the mode-I intralaminar toughness of a hybrid plain weave composite laminate manufactured using resin infusion under flexible tooling (RIFT) process is presented in this paper. The pre-cracked geometries consisted of overheight compact tension (OCT), double edge notch (DEN) and centrally cracked four-point-bending (4PBT) test specimens. The position as well as the strain field ahead of the crack tip during the loading stage was determined using a digital speckle photogrammetry system. The limitation on the applicability of the standard data reduction schemes for the determination of intralaminar toughness of composite materials is presented and discussed. A methodology based on the numerical evaluation of the strain energy release rate using the J-integral method is proposed to derive new geometric correction functions for the determination of the stress intensity factor for composites. The method accounts for material anisotropy and finite specimen dimension effects regardless of the geometry. The approach has been validated for alternative non-standard specimen geometries. A comparison between different methods currently available for computing the intralaminar fracture toughness in composite laminates is presented and a good agreement between numerical and experimental results using the proposed methodology was obtained. 

Performance and wear of coated carbide drill in machining of carbon fibre reinforced composite/titanium stack

In this research we investigate the performance of drilling process in carbon fibre reinforced composite (CFC) material, titanium alloy and the hybrid stack of these two materials, using coated carbide drill bit. We study the effect of the process parameters such as the feed rate and speed on the induced forces and torques, also on the wear of drill and surface roughness of the holes. In the composite material the percentage of surface damage in both drilling CFC on its own and drilling in stack form is estimated. Also, the effect of worn drill on the surface damage is identified. In the titanium, the burr formation in stack and non-stack form is investigated. The wear of the drill results in increased forces and torques required for drilling. This increases the surface delaminations substantially at the entrance in drilling of CFC. However, the surface roughness of the holes reduces with the wear of the drill in CFC drilling. Also, the surface delamination and surface roughness of the holes in the CFC whilst drilled in hybrid form reduces significantly. This is despite the increase of the forces and torques required in drilling CFC in stack form. Copyright © 2012 Inderscience Enterprises Ltd.