Brian Falzon

Postbuckling behaviour of a blade-stiffened composite panel loaded in uniaxial compression

Abstract The postbuckling behaviour of a panel with blade-stiffeners incorporating tapered flanges was experimentally investigated. A new failure mechanism was identified for this particular type of stiffener. Failure was initiated by mid-plane delamination at the free edge of the postbuckled stiffener web at a node-line. This was consistent with an interlaminar shear stress failure and was calculated from strain gauge measurements using an approximate analysis based on lamination theory and incorporating edge effects. The critical shear stress was found to agree well with the shear strength obtained from a three-point bending test of the web laminate.

Buckling mode transition in hat-stiffened composite panels loaded in uniaxial compression

Abstract A combined experimental and analytical study of a hat-stiffened carbon-fibre composite panel loaded in uniaxial compression was investigated. A buckling mode transition was observed in the panels skin bay which was not captured using non-linear finite-element analysis. Good correlation between experimental and numerical strain and displacement results was achieved in the prebuckling and initial postbuckling region of the loading history. A Marguerre-type Rayleigh-Ritz energy method was applied to the skin bay using representative displacement functions of permissible mode shapes to explain the mode transition phenomenon. The central criterion of this method was based on the assumption that a change in mode shape occurred such that the total potential energy of the structure was maintained at a minimum. The ultimate strength of the panel was limited by the column buckling strength of the hat-stiffeners.

Optimization strategy for minimizing damage in postbuckling stiffened panels

Composite materials are finding increasing use on primary aerostructures to meet demanding performance targets while reducing environmental impact. This paper presents a finite-element-based preliminary optimization methodology for postbuckling stiffened panels, which takes into account damage mechanisms that lead to delamination and subsequent failure by stiffener debonding. A global-local modeling approach is adopted in which the boundary conditions on the local model are extracted directly from the global model. The optimization procedure is based on a genetic algorithm that maximizes damage resistance within the postbuckling regime. This routine is linked to a finite element package and the iterative procedure automated. For a given loading condition, the procedure optimized the stacking sequence of several areas of the panel, leading to an evolved panel that displayed superior damage resistance in comparison with nonoptimized designs.

Failure of thick-skinned stiffener runout sections loaded in uniaxial compression

Abstract Recent efforts towards the development of the next generation of large civil and military transport aircraft within the European community have provided new impetus for investigating the potential use of composite material in the primary structure. One concern in this development is the vulnerability of co-cured stiffened structures to through-thickness stresses at the skin–stiffener interfaces particularly in stiffener runout regions. These regions are an inevitable consequence of the requirement to terminate stiffeners at cutouts, rib intersections or other structural features which interrupt the stiffener load path. In this respect, thicker-skinned components are more vulnerable than thin-skinned ones. This work presents an experimental and numerical study of the failure of thick-sectioned stiffener runout specimens loaded in uniaxial compression. The experiments revealed that failure was initiated at the edge of the runout and propagated across the skin–stiffener interface. High frictional forces at the edge of the runout were also deduced from a fractographic analysis and it is postulated that these forces may enhance the fracture toughness of the specimens. Finite element analysis using an efficient thick-shell element and the Virtual Crack Closure Technique was able to qualitatively predict the crack growth characteristics for each specimen.

The behaviour of damage tolerant hat-stiffened composite panels loaded in uniaxial compression

Damage tolerant hat-stiffened thin-skinned composite panels with and without a centrally located circular cutout, under uniaxial compression loading, were investigated experimentally and analytically. These panels incorporated a highly postbuckling design characterised by two integral stiffeners separated by a large skin bay with a high width to skin-thickness ratio. In both configurations, the skin initially buckled into three half-wavelengths and underwent two mode-shape changes; the first a gradual mode change characterised by a central deformation with double curvature and the second a dynamic snap to five half-wavelengths. The use of standard path-following non-linear finite element analysis did not consistently capture the dynamic mode change and an approximate solution for the prediction of mode-changes using a Marguerre-type Rayleigh-Ritz energy method is presented. Shortcomings with both methods of analysis are discussed and improvements suggested. The panels failed catastrophically and their strength was limited by the local buckling strength of the hat stiffeners.

Shape optimization of interior cutouts in composite panels

This paper presents validated results of the optimization of cutouts in laminated carbon-fibre composite panels by adapting a recently developed optimization procedure known as Evolutionary Structural Optimization (ESO). An initial small cutout was introduced into each finite element model and elements were removed from around this cutout based on a predefined rejection criterion. In the examples presented, the limiting ply within each plate element around the cutout was determined based on the Tsai-Hill failure index. Plates with values below the product of the average Tsai-Hill number and a rejection ratio (RR) were subsequently removed. This process was iterated until a steady state was reached and the RR was then incremented by an evolutionary rate (ER). The above steps were repeated until a cutout of a desired area was achieved.

Capturing mode-switching in postbuckling composite panels using a modified explicit procedure

A postbuckling blade-stiffened composite panel was loaded in uniaxial compression, until failure. During loading beyond initial buckling, this panel was observed to undergo a secondary instability characterised by a dynamic mode shape change. These abrupt changes cause considerable numerical difficulties using standard path-following quasi-static solution procedures in finite element analysis. Improved methods such as the arc-length-related procedures do better at traversing certain critical points along an equilibrium path but these procedures may also encounter difficulties in highly non-linear problems. This paper presents a robust, modified explicit dynamic analysis for the modelling of postbuckling structures. This method was shown to predict the mode-switch with good accuracy and is more efficient than standard explicit dynamic analysis.

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 tools predictive capabilities.

Buckling and Postbuckling Structures: Experimental, Analytical and Numerical Studies

Experimental Studies of Stiffened Composite Panels under Axial Compression, Torsion and Combined Loading (H Abramovich) Buckling and Postbuckling Tests on Stiffened Composite Panels and Shells (C Bisagni) Mode-Jumping in Postbuckling Stiffened Composite Panels (B G Falzon) The Response of Compression-Loaded Shells with Cutouts (M W Hilburger) Stability Design of Stiffened Composite Panels -- Simulation and Experimental Validation (A Kling) Anisotropic Elastic Tailoring in Laminated Composite Plates and Shells (P M Weaver) Optimization of Stiffened Panels Using Finite Strip Models (R Butler) Stability of Tubes and Pipelines (H Rasheed & S Karamanos) Imperfection-Sensitive Buckling and Postbuckling of Spherical Shell Caps (S Yamada) Nonlinear Buckling in Sandwich Struts: Mode Interaction and Localization (M A Wadee) The Boundary Element Method for Instability Analysis of Shear Deformable Plates and Shells (M H Aliabadi et al.) Progressive Failure in Compressively Loaded Composite Laminated Panels (S Basu et al.) Micro- and Meso-Instabilities in Structured Materials and Material Compounds (F G Rammerstorfer et al.).

Use of arc-length method for capturing mode jumping in postbuckling aerostructures

The arc-length method has become a widely established solution technique for studying nonlinear structural behavior. By augmenting the set of nonlinear equilibrium equations with a constraint equation, which is a function of both the displacements and load increment, it is capable of traversing limit points. Numerous investigations have shown that highly nonlinear behavior such as sharp snap-backs can still lead to numerical difficulties. Two practical examples are presented to assess the effectiveness of this solution technique in capturing secondary instabilities in postbuckling structures, which present themselves as abrupt mode jumps. Although the first example poses no special difficulties, in the second case the nonlinear procedure fails to converge. An improvement to the methods formulation is suggested, which accounts for the residual forces that are usually neglected, when proceeding to the next increment once convergence is reached on the current increment. The choice of a correct load increment at the first iteration, within a predictor-corrector scheme, is central to the methods effectiveness. Current strategies for a choice of this load increment are discussed and are shown to be no longer consistent with the modified formulation; therefore, a new approach is proposed.