Numerical evaluation of three-dimensional scarf repairs in carbon-epoxy structures

The widespread employment of carbon-epoxy laminates in high responsibility and severely loaded applications introduces an issue regarding their handling after damage. Repair of these structures should be evaluated, instead of their disposal, for cost saving and ecological purposes. Under this perspective, the availability of efficient repair methods is essential to restore the strength of the structure. The development and validation of accurate predictive tools for the repairs behaviour are also extremely important, allowing the reduction of costs and time associated to extensive test programmes. Comparing with strap repairs, scarf repairs have the advantages of a higher efficiency and the absence of aerodynamic disturbance. This work reports on a numerical study of the tensile behaviour of three-dimensional scarf repairs in carbon-epoxy structures, using a ductile adhesive (Araldite® 2015). The finite elements analysis was performed in ABAQUS® and Cohesive Zone Modelling was used for the simulation of damage onset and growth in the adhesive layer. Trapezoidal cohesive laws in each pure mode were used to account for the ductility of the specific adhesive mentioned. A parametric study was performed on the repair width and scarf angle. The use of over-laminating plies covering the repaired region at the outer or both repair surfaces was also tested as an attempt to increase the repairs efficiency. The obtained results allowed the proposal of design principles for repairing composite structures.

Optimizing the embedded heaters position in the pultrusion process using finite element analysis

This study is based on a previous experimental work in which embedded cylindrical heaters were applied to a pultrusion machine die, and resultant energetic performance compared with that achieved with the former heating system based on planar resistances. The previous work allowed to conclude that the use of embedded resistances enhances significantly the energetic performance of pultrusion process, leading to 57% decrease of energy consumption. However, the aforementioned study was developed with basis on an existing pultrusion die, which only allowed a single relative position for the heaters. In the present work, new relative positions for the heaters were investigated in order to optimize heat distribution process and energy consumption. Finite Elements Analysis was applied as an efficient tool to identify the best relative position of the heaters into the die, taking into account the usual parameters involved in the process and the control system already tested in the previous study. The analysis was firstly developed with basis on eight cylindrical heaters located in four different location plans. In a second phase, in order to refine the results, a new approach was adopted using sixteen heaters with the same total power. Final results allow to conclude that the correct positioning of the heaters can contribute to about 10% of energy consumption reduction, decreasing the production costs and leading to a better eco-efficiency of pultrusion process.

Avaliação do desempenho de ligações tubulares em estruturas de veículos pesados de passageiros por simulação numérica

Nesta Dissertação ir-se-á avaliar o desempenho de algumas ligações existentes nos veículos pesados de passageiros, através do Regulamento Eurocódigo 3. Nos últimos anos ocorreram diversos acidentes envolvendo este tipos de veículos, em que os mesmos causaram vítimas mortais e feridos graves. Serão testadas por simulação numérica algumas ligações pertencentes a elementos constituintes da superestrutura, em que esta é normalmente afectada com a ocorrência de acidentes. Assim sendo, o estudo de nós de ligação tem uma importância fulcral para que uma superestrutura suporte situações extremas e que resista a solicitações externas aplicadas. Iniciou-se esta Dissertação com o estudo da sinistralidade e de acidentes que envolvem veículos pesados de passageiros. No capítulo 2 abordou-se um programa que promove simulações numéricas de acidentes e estudo do comportamento dos passageiros em caso de acidente, sendo referido o Regulamento que homologa os veículos pesados de passageiros e os seus principais métodos. Abordaram-se os principais constituintes da estrutura de um veículo pesado de passageiros. No capítulo 3, é referido o Eurocódigo 3 em termos do estudo das ligações tubulares usadas neste tipo de veículos. No capítulo 4, fez-se o estudo e selecção de elementos a utilizar para a simulação numérica de casos preconizados pelo Eurocódigo 3 e estudaram-se três tipos de ligações que são usadas na construção da superestrutura deste tipo de veículos, tendo-se retirado conclusões deste estudo.

Adhesive selection for single lap bonded joints: Experimentation and advanced techniques for strength prediction

The integrity of multi-component structures is usually determined by their unions. Adhesive-bonding is often used over traditional methods because of the reduction of stress concentrations, reduced weight penalty, and easy manufacturing. Commercial adhesives range from strong and brittle (e.g., Araldite® AV138) to less strong and ductile (e.g., Araldite® 2015). A new family of polyurethane adhesives combines high strength and ductility (e.g., Sikaforce® 7888). In this work, the performance of the three above-mentioned adhesives was tested in single lap joints with varying values of overlap length (LO). The experimental work carried out is accompanied by a detailed numerical analysis by finite elements, either based on cohesive zone models (CZM) or the extended finite element method (XFEM). This procedure enabled detailing the performance of these predictive techniques applied to bonded joints. Moreover, it was possible to evaluate which family of adhesives is more suited for each joint geometry. CZM revealed to be highly accurate, except for largely ductile adhesives, although this could be circumvented with a different cohesive law. XFEM is not the most suited technique for mixed-mode damage growth, but a rough prediction was achieved.

Strength improvement of adhesively-bonded scarf repairs in aluminium structures with external reinforcements

Adhesively bonded techniques are an attractive option to repair aluminium structures, compared to more traditional methods. Actually, as a result of the improvement in the mechanical characteristics of adhesives, adhesive bonding has progressively replaced the traditional joining methods. There are several bonded repair configurations, as single-strap, double-strap and scarf. Compared with strap repairs, scarf repairs have the advantages of a higher efficiency and the absence of aerodynamic disturbance. The higher efficiency is caused by the elimination of the significant joint eccentricities of strap repairs. Moreover, stress distributions along the bond length are more uniform, due to tapering of the scarf edges. The main disadvantages of this technique are the difficult machining of the surfaces, associated costs and requirement of specialised labour. This work reports on an experimental and numerical study of the tensile behaviour of two-dimensional (2D) scarf repairs of aluminium structures bonded with the ductile epoxy adhesive Araldite® 2015. The numerical analysis, by Finite Elements (FE), was performed in Abaqus® and used cohesive zone models (CZM) for the simulation of damage onset and growth in the adhesive layer, thus enabling the strength prediction of the repairs. A parametric study was performed on the scarf angle (α) and different configurations of external reinforcement (applied on one or two sides of the repair, and also different reinforcement lengths). The obtained results allowed the establishment of design guidelines for repairing, showing that the use of external reinforcements enables increasing α for equal strength recovery, which makes the repair procedure easier. The numerical technique was accurate in predicting the repairs’ strength, enabling its use for design and optimisation purposes.

Projeto da estrutura e sistema de movimentação robotizado de linha automática de corte de chapa

Os robots de movimentação de chapa são bastantes úteis para as empresas de metalomecânica. De facto, cada vez mais existem máquinas de corte por jato de água, laser ou outros processos, nos quais os robots apresentam um papel importante na carga e descarga do material. O trabalho realizado apresenta novas soluções aos sistemas de movimentação existentes no mercado, e permite reduzir os custos na movimentação do material. Este projeto serve essencialmente para chapas em trajetória retilínea, e efetuar o seu levantamento do equipamento e deposição em estrutura de suporte (ou viceversa). A vantagem a ter em conta é a diminuição dos custos de movimentação do material. Neste trabalho apresentou-se a metodologia de dimensionamento de um robot automatizado que transporta chapas com um peso máximo de 3500 kg, tendo por base as normas do EC3-P1.8 e o Método de Elementos Finitos (MEF). No decurso do projeto foram abordadas os seguintes temas: Abordagem inicial da geometria através do Solidworks; Dimensionamento da estrutura por software de Elementos Finitos, o Solidworks; Dimensionamento das correntes, carretos/discos ou coroas e rolamentos; Dimensionamento e seleção dos moto-redutores, bomba de vácuo e ventosas; Cálculo das solicitações em cada membro da estrutura por software de análise estrutural, o Multiframe3D, e respetivo dimensionamento das ligações aparafusadas e soldadas; Elaboração dos desenhos de projeto finais, processos de fabrico e custos; Dimensionamento do acionamento, MG e disposição dos dispositivos no quadro elétrico. Como conclusão refere-se que se conseguiu realizar o projeto e obter uma solução final otimizada, com a ajuda de ferramentas importantes, como sejam o MEF, resultando num equipamento cujas solicitações para a estrutura e sistema de movimentação foram otimizadas, resultando num equipamento eficiente, robusto, seguro e de custo reduzido.

Comparação dos efeitos secundários agudos da Radioterapia por intensidade modulada com a Radioterapia tridimensional conformada no carcinoma de próstata

Introdução: Este trabalho tem como principal objectivo comparar os efeitos secundários agudos da Radioterapia por Intensidade Modulada (IMRT) e a Radioterapia Tridimensional Conformada (3 D-CRT) no carcinoma de Próstata; Materiais e métodos: Foram observados os processos clínicos de 30 doentes e analisados os efeitos colaterais da RT ocorridos no decurso do tratamento. Resultados: A percentagem de toxicidade aguda dermatológica foi superior no grupo tratado com 3D-CRT. Nenhum doente apresentou toxicidade aguda grave. Conclusões: O tamanho reduzido da amostra e a ausência de valores estatisticamente significativos, não permite concluir a influência da técnica de RT no desenvolvimento de efeitos secundários agudos.

Using a cohesive damage model to predict the tensile behaviour of CFRP single-strap repairs

This work addresses both experimental and numerical analyses regarding the tensile behaviour of CFRP single-strap repairs. Two fundamental geometrical parameters were studied: overlap length and patch thickness. The numerical model used ABAQUS® software and a developed cohesive mixed-mode damage model adequate for ductile adhesives, and implemented within interface finite elements. Stress analyses and strength predictions were carried out. Experimental and numerical comparisons were performed on failure modes, failure load and equivalent stiffness of the repair. Good correlation was found between experimental and numerical results, showing that the proposed model can be successfully applied to bonded joints or repairs.

Interlaminar fracture characterization of a carbon-epoxy composite in pure mode II

The interlaminar fracture toughness in pure mode II (GIIc) of a Carbon-Fibre Reinforced Plastic (CFRP) composite is characterized experimentally and numerically in this work, using the End-Notched Flexure (ENF) fracture characterization test. The value of GIIc was extracted by a new data reduction scheme avoiding the crack length measurement, named Compliance-Based Beam Method (CBBM). This method eliminates the crack measurement errors, which can be non-negligible, and reflect on the accuracy of the fracture energy calculations. Moreover, it accounts for the Fracture Process Zone (FPZ) effects. A numerical study using the Finite Element Method (FEM) and a triangular cohesive damage model, implemented within interface finite elements and based on the indirect use of Fracture Mechanics, was performed to evaluate the suitability of the CBBM to obtain GIIc. This was performed comparing the input values of GIIc in the numerical models with the ones resulting from the application of the CBBM to the numerical load-displacement (P-) curve. In this numerical study, the Compliance Calibration Method (CCM) was also used to extract GIIc, for comparison purposes.

The influence of the boundary conditions on low-velocity impact composite damage

The objective of this work was to study the influence of the boundary conditions on low-velocity impact behaviour of carbon-epoxy composite plates. Experimental work and numerical analysis were performed on [04,904]s laminates. The influence of different boundary conditions on the impacted plates was analysed considering rectangular and square plates. The X-radiography was used as a non-destructive technique to evaluate the internal damage caused by impact loading. A three-dimensional numerical analysis was also performed considering progressive damage modelling. The model includes three-dimensional solid elements and interface finite elements including a cohesive mixed-mode damage model, which allows simulating delamination between different oriented layers. It was verified that plate’s boundary conditions have influence on the delaminated area. Good agreement between experimental and numerical analysis for shape, orientation and size of the delamination was obtained.

Single-lap joints of similar and dissimilar adherends bonded with an acrylic adhesive

In this study, the tensile strength of single-lap joints (SLJs) between similar and dissimilar adherends bonded with an acrylic adhesive was evaluated experimentally and numerically. The adherend materials included polyethylene (PE), polypropylene (PP), carbon-epoxy (CFRP), and glass-polyester (GFRP) composites. The following adherend combinations were tested: PE/PE, PE/PP, PE/CFRP, PE/GFRP, PP/PP, CFRP/CFRP, and GFRP/GFRP. One of the objectives of this work was to assess the influence of the adherends stiffness on the strength of the joints since it significantly affects the peel stresses magnitude in the adhesive layer. The experimental results were also used to validate a new mixed-mode cohesive damage model developed to simulate the adhesive layer. Thus, the experimental results were compared with numerical simulations performed in ABAQUS®, including a developed mixed-mode (I+II) cohesive damage model, based on the indirect use of fracture mechanics and implemented within interface finite elements. The cohesive laws present a trapezoidal shape with an increasing stress plateau, to reproduce the behaviour of the ductile adhesive used. A good agreement was found between the experimental and numerical results.

Estruturas de suporte de terras executadas com pneus

O aproveitamento de pneus em fim de vida revela ser uma alternativa eficaz e promissora na indústria da construção civil, na utilização deste resíduo em muros de suporte. O presente trabalho tem como principal objetivo a apresentação de uma técnica de aproveitamento de pneus em fim de vida na execução de muros de gravidade, combinando solo e pneus. Neste sentido, tomou-se como referência um estudo realizado no Brasil por Sieira, Sayão, Medeiros e Gerscovich, para avaliar a eficiência e o custo deste tipo de estruturas, comparando-o com um muro de suporte tradicional de betão simples. Inicialmente, avaliou-se a segurança do muro de solo-pneus, de acordo com a metodologia proposta no Eurocódigo 7 (NP EN 1997-1, 2010), considerando a geometria e as características dos materiais apresentados no estudo referido e usando o programa de cálculo automático Slide, da Rocscience, para a verificação da estabilidade global. Reproduziu-se a análise numérica realizada no âmbito do caso de estudo brasileiro de referência, recorrendo também a uma formulação por elementos finitos com o programa de cálculo automático Phase2, da Rocscience. Por último, utilizando uma vez mais o programa Slide, definiu-se a geometria de um muro de betão simples cuja geometria garantisse o mesmo valor do fator de segurança à estabilidade global, obtido com o muro de solo-pneus e compararam-se os custos respetivos. O presente trabalho confirmou a eficiência e o baixo custo desta solução construtiva, sendo necessários, no entanto, estudos mais detalhados que reforcem estas conclusões.

Efeito de alterações geométricas na resistência de juntas de sobreposição

A utilização de juntas coladas em aplicações industriais tem vindo a aumentar nos últimos anos, em detrimento dos métodos tradicionais de ligação tais como a soldadura, brasagem, ligações aparafusadas e rebitadas. As juntas de sobreposição simples são o tipo de juntas mais frequentemente utilizadas em aplicações industriais, porque são as mais simples de fabricar. No entanto, a aplicação descentrada da carga neste tipo de junta provoca efeitos de flexão que originam o aparecimento de tensões normais na direção da espessura do adesivo (arrancamento), reduzindo assim a resistência da junta colada. De uma maneira geral, existem dois tipos de métodos para reduzir as concentrações de tensões. O primeiro é utilizar alterações no próprio material, otimizando as propriedades do adesivo e do substrato, enquanto o segundo método envolve alterar a geometria da junta, como por exemplo utilizando filetes de adesivo, chanfros nas extremidades dos substratos, aplicar uma geometria ondulada ou dobrar os substratos na zona de sobreposição, ou ainda utilizar rasgos nos substratos ao longo da sobreposição. Neste trabalho é realizado um estudo experimental e numérico por Elementos Finitos de duas alterações efetuadas à geometria de juntas de sobreposição simples, de modo a aumentar a sua resistência comparativamente às juntas sem alteração geométrica. A primeira condição efetuada foi a utilização de rasgos nas extremidades do comprimento de sobreposição e a segunda foi a utilização de rasgos a meio do comprimento de sobreposição. No final do estudo experimental, verificou-se que a resistência da ligação foi significativamente melhorada com algumas das configurações testadas para cada alteração, e foi possível estabelecer em ambos os casos a configuração ótima. Numa fase posterior, procedeu-se à simulação numérica, que incluiu uma análise de tensões e previsão do comportamento das juntas através de modelos de dano coesivo. A análise permitiu obter os modos de rotura, as curvas força-deslocamento e a resistência das juntas. Obteve-se uma concordância bastante boa com os resultados experimentais, o que mostrou a adequabilidade do método de previsão proposto para estimar o comportamento das juntas.

Optimising the energy consumption on pultrusion process

This study is based on a previous experimental work in which embedded cylindrical heaters were applied to a pultrusion machine die, and resultant energetic performance compared with that achieved with the former heating system based on planar resistances. The previous work allowed to conclude that the use of embedded resistances enhances significantly the energetic performance of pultrusion process, leading to 57% decrease of energy consumption. However, the aforementioned study was developed with basis on an existing pultrusion die, which only allowed a single relative position for the heaters. In the present work, new relative positions for the heaters were investigated in order to optimise heat distribution process and energy consumption. Finite Elements Analysis was applied as an efficient tool to identify the best relative position of the heaters into the die, taking into account the usual parameters involved in the process and the control system already tested in the previous study. The analysis was firstly developed based on eight cylindrical heaters located in four different location plans. In a second phase, in order to refine the results, a new approach was adopted using sixteen heaters with the same total power. Final results allow to conclude that the correct positioning of the heaters can contribute to about 10% of energy consumption reduction, decreasing the production costs and leading to a better eco-efficiency of pultrusion process.

Strap repairs using embedded patches: numerical analysis and experimental results

Adhesively bonded repairs offer an attractive option for repair of aluminium structures, compared to more traditional methods such as fastening or welding. The single-strap (SS) and double-strap (DS) repairs are very straightforward to execute but stresses in the adhesive layer peak at the overlap ends. The DS repair requires both sides of the damaged structures to be reachable for repair, which is often not possible. In strap repairs, with the patches bonded at the outer surfaces, some limitations emerge such as the weight, aerodynamics and aesthetics. To minimize these effects, SS and DS repairs with embedded patches were evaluated in this work, such that the patches are flush with the adherends. For this purpose, in this work standard SS and DS repairs, and also with the patches embedded in the adherends, were tested under tension to allow the optimization of some repair variables such as the overlap length (LO) and type of adhesive, thus allowing the maximization of the repair strength. The effect of embedding the patch/patches on the fracture modes and failure loads was compared with finite elements (FE) analysis. The FE analysis was performed in ABAQUS® and cohesive zone modelling was used for the simulation of damage onset and growth in the adhesive layer. The comparison with the test data revealed an accurate prediction for all kinds of joints and provided some principles regarding this technique.