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.

Caracterização experimental e modelação numérica de espumas metálicas

As espumas de alumínio são materiais ultraleves, o que as torna atractivas para um largo espectro de aplicações comerciais na área da defesa, na indústria automóvel e aeroespacial, entre outras. Actualmente, há um grande interesse na utilização de espumas de alumínio em componentes estruturais ultraleves, incorporados em sistemas de absorção de energia para protecção contra o impacto. O recurso à simulação numérica para resolver problemas de engenharia em várias áreas é cada vez mais comum. A modelação numérica dos materiais assume vital importância quando o problema envolve a análise de processos tecnológicos como, por exemplo, a conformação plástica de materiais, ou a análise de estruturas. Deste modo, torna-se imprescindível garantir que a modelação dos materiais é de tal forma rigorosa que permite simular o melhor possível o seu comportamento real nas condições concretas da análise a realizar. A forma mais comum de garantir o rigor dos modelos utilizados é a validação dos modelos numéricos tendo por base resultados experimentais. Neste trabalho, fez-se a caracterização do comportamento mecânico das espumas de alumínio com nome comercial ALPORAS!, obtidas pelo processo de fabrico denominado expansão directa do metal fundido por adição de um agente expansor. Esta caracterização consistiu num conjunto de ensaios experimentais quer no regime quasi-estático, quer no regime dinâmico. No regime quasi-estático realizaram-se ensaios de compressão uniaxial e de compressão multiaxial. Para a caracterização no regime dinâmico foram realizados ensaios em barras de Hopkinson de polimetil-metacrilato (PMMA). Com base nos resultados experimentais obtidos determinaram-se os parâmetros dos dois modelos constitutivos para espumas metálicas implementados no programa comercial Abaqus™/Explicit. Estes modelos, e os respectivos parâmetros determinados, foram validados reproduzindo numericamente alguns ensaios experimentais quasi-estáticos e dinâmicos. Assim, verificou-se a adequabilidade dos modelos em diversas condições quer em termos de esforços quer em termos de regime de taxa de deformação Por último, desenvolveu-se uma estrutura inovadora para absorção de energia durante um impacto, constituída por componentes perfilados em liga de alumínio e por componentes em espumas de alumínio. Esta estrutura foi testada exclusivamente com recurso à simulação numérica, utilizando os modelos constitutivos validados anteriormente.

Numerical tools for isogeometric analysis in the nonlinear regime

The present work deals with the development of robust numerical tools for Isogeometric Analysis suitable for problems of solid mechanics in the nonlinear regime. To that end, a new solid-shell element, based on the Assumed Natural Strain method, is proposed for the analysis of thin shell-like structures. The formulation is extensively validated using a set of well-known benchmark problems available in the literature, in both linear and nonlinear (geometric and material) regimes. It is also proposed an alternative formulation which is focused on the alleviation of the volumetric locking pathology in linear elastic problems. In addition, an introductory study in the field of contact mechanics, in the context of Isogeometric Analysis, is also presented, with special focus on the implementation of a the Point-to-Segment algorithm. All the methodologies presented in the current work were implemented in a in-house code, together with several pre- and post-processing tools. In addition, user subroutines for the commercial software Abaqus were also implemented.

Optimization study of hybrid spot-welded/bonded single-lap joints

Joining of components with structural adhesives is currently one of the most widespread techniques for advanced structures (e.g., aerospace or aeronautical). Adhesive bonding does not involve drilling operations and it distributes the load over a larger area than mechanical joints. However, peak stresses tend to develop near the overlap edges because of differential straining of the adherends and load asymmetry. As a result, premature failures can be expected, especially for brittle adhesives. Moreover, bonded joints are very sensitive to the surface treatment of the material, service temperature, humidity and ageing. To surpass these limitations, the combination of adhesive bonding with spot-welding is a choice to be considered, adding a few advantages like superior static strength and stiffness, higher peeling and fatigue strength and easier fabrication, as fixtures during the adhesive curing are not needed. The experimental and numerical study presented here evaluates hybrid spot-welded/bonded single-lap joints in comparison with the purely spot-welded and bonded equivalents. A parametric study on the overlap length (LO) allowed achieving different strength advantages, up to 58% compared to spot-welded joints and 24% over bonded joints. The Finite Element Method (FEM) and Cohesive Zone Models (CZM) for damage growth were also tested in Abaqus® to evaluate this technique for strength prediction, showing accurate estimations for all kinds of joints.

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.

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.

Strength improvement of adhesively-bonded joints using a reverse-bent geometry

Adhesive bonding of components has become more efficient in recent years due to the developments in adhesive technology, which has resulted in higher peel and shear strengths, and also in allowable ductility up to failure. As a result, fastening and riveting methods are being progressively replaced by adhesive bonding, allowing a big step towards stronger and lighter unions. However, single-lap bonded joints still generate substantial peel and shear stress concentrations at the overlap edges that can be harmful to the structure, especially when using brittle adhesives that do not allow plasticization in these regions. In this work, a numerical and experimental study is performed to evaluate the feasibility of bending the adherends at the ends of the overlap for the strength improvement of single-lap aluminium joints bonded with a brittle and a ductile adhesive. Different combinations of joint eccentricity were tested, including absence of eccentricity, allowing the optimization of the joint. A Finite Element stress and failure analysis in ABAQUS® was also carried out to provide a better understanding of the bent configuration. Results showed a major advantage of using the proposed modification for the brittle adhesive, but the joints with the ductile adhesive were not much affected by the bending technique.

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.

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.

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.

Estudo e otimização de juntas do tipo Tpeel soldadas, adesivas e híbridas

A necessidade de utilizar métodos de ligação que melhor satisfaçam as necessidades de projeto tem causado a crescente utilização das juntas adesivas, em detrimento dos métodos tradicionais tais como a soldadura, ligações aparafusadas e rebitadas. A sua utilização em diversas aplicações industriais justifica-se pela redução de peso, redução de concentrações de tensões, isolamento acústico e melhor resistência à corrosão. Contudo, também apresentam desvantagens, como a necessidade de preparação das juntas, a fraca resistência a esforços de arrancamento e a complexidade da previsão da sua resistência. As juntas híbridas são obtidas por combinação de uma técnica tradicional com uma ligação adesiva. As juntas híbridas adesivas-soldadas obtêm-se através da combinação da ligação adesiva com a ligação soldada, sendo a soldadura de resistência por pontos a técnica de soldadura mais usada no fabrico deste tipo de juntas. A sinergia entre ligação adesiva e soldadura por pontos oferece vantagens competitivas em relação às ligações adesivas, tais como superior resistência e rigidez, e maior resistência ao arrancamento e à fadiga. No presente trabalho é apresentado um estudo experimental e numérico de juntas T-peel soldadas, adesivas e híbridas (adesivas-soldadas) solicitadas ao arrancamento. Considerouse o adesivo frágil Araldite® AV138 e os adesivos dúcteis Araldite® 2015 e Sikaforce® 7752 e aderentes de aço (C45E). Foi realizada uma análise dos valores experimentais e efetuada uma comparação destes valores com os resultados obtidos pelo Método de Elementos Finitos (MEF) no software ABAQUS®, que incluiu uma análise de tensões na camada de adesivo e previsão do comportamento das juntas por MDC. Observou-se que, dos três adesivos em estudo, o adesivo Sikaforce® 7752 é o que apresenta o melhor desempenho na ligação de juntas T-peel. A boa concordância entre os resultados experimentais e numéricos permitiu validar a utilização de MDC para previsão da resistência de juntas T-peel adesivas e híbridas. Assim, o presente trabalho representa uma base para posterior aplicação no projeto deste tipo de ligação, com as vantagens decorrentes na redução do tempo de projeto e maior facilidade de otimização.