M.F.S.F. de Moura

Numerical simulation of mixed-mode progressive delamination in composite materials

A new decohesion element with the capability of dealing with crack propagation under mixed-mode loading is proposed and demonstrated. The element is used at the interface between solid finite elements to model the initiation and non-self-similar growth of delaminations in composite materials. A single relative displacement-based damage parameter is applied in a softening law to track the damage state of the interface and to prevent the restoration of the cohesive state during unloading. The softening law is applied in the three-parameter Benzeggagh-Kenane mode interaction criterion to predict mixed-mode delamination propagation. To demonstrate the accuracy of the predictions, steady-state delamination growth is simulated for quasi-static loading of various single mode and mixed-mode delamination test specimens and the results are compared with experimental data.

Effect of Adhesive Type and Thickness on the Lap Shear Strength

The effect of the adhesive thickness on the bond strength of single-lap adhesive joints is still not perfectly understood. The classical elastic analyses predict that the strength increases with the adhesive thickness, whereas experimental results show the opposite. Various theories have been proposed to explain this discrepancy, but more experimental tests are necessary to understand all the variables. The objective of the present study was to assess the effect of the adhesive thickness on the strength of single-lap joints for different kinds of adhesives. Three different adhesives were selected and tested in bulk. The strain to failure in tension ranged from 1.3% for the most brittle adhesive to 44% for the most ductile adhesive. The adherend selected was a high-strength steel to keep the adherends in the elastic range and simplify the analysis. Three thicknesses were studied for each adhesive: 0.2, 0.5, and 1 mm. A statistical analysis of the experimental results shows that the lap shear strength increases as the bondline gets thinner and the adhesive gets tougher.

A three-dimensional finite element model for stress analysis of adhesive joints

Abstract This paper presents a new model for three-dimensional finite element analysis of adhesive joints. The model considers geometric and material nonlinearities and uses solid brick elements as well as specially developed interface elements. The interface elements allow the calculation of stresses at the adherend–adhesive interfaces. The application of the model to a single-lap joint is presented. The results of a linear elastic analysis highlight the three-dimensional nature of the stresses and stress concentrations at interfaces. The influence of material nonlinearities on the behavior of the joint is also discussed.

Mode-I interlaminar fracture of carbon/epoxy cross-ply composites

Abstract Mode-I double-cantilever beam (DCB) tests were performed on carbon/epoxy [0°/90°]12 specimens. The starter crack was created at mid-thickness, between the 0 and 90° mid-layers. During the tests, however, the crack also propagated along the neighbouring 0°/90° interface and within the 90° mid-layer. Nevertheless, the test results were apparently consistent with the assumptions of the corrected beam theory (CBT) that was used to obtain the interlaminar critical strain energy release rate, GIc. The measured values were higher than those of unidirectional [0°]24 specimens, especially the final propagation values. A finite-element analysis confirmed the applicability of the CBT for interlaminar propagation along the two 0°/90° interfaces. The results also indicated that the intralaminar GIc is significantly smaller than the interlaminar GIc. This will prevent pure interlaminar propagation in multi-directional specimens with high interlaminar fracture toughness.

Prediction of low velocity impact damage in carbon–epoxy laminates

It is well known that composite laminates are easily damaged by low velocity impact. This event causes internal delaminations that can drastically reduce the compressive strength of laminates. In this study, numerical and experimental analyses for predicting the damage in carbon–epoxy laminates, subjected to low velocity impact, were performed. Two different laminates (04,904)s and (02,±452,902)s were tested using a drop weight testing machine. Damage characterisation was carried out using X-rays radiography and the deply technique. The developed numerical model is based on a special shell finite element that guarantees interlaminar shear stresses continuity between different oriented layers, which was considered fundamental to predict delaminations. In order to predict the occurrence of matrix failure and the delaminated areas, a new failure criterion based on experimental observations and on other developed criteria, is included. A good agreement between experimental and numerical analysis for shape and orientation of delaminations was obtained. For delaminated areas, reasonable agreement was obtained.

Interface element including point‐to‐surface constraints for three‐dimensional problems with damage propagation

An interface finite element for three‐dimensional problems based on the penalty method is presented. The proposed element can model joints/interfaces between solid finite elements and also includes the propagation of damage in pure mode I, pure mode II and mixed mode considering a softening relationship between the stresses and relative displacements. Two different contact conditions are considered: point‐to‐point constraint for closed points (not satisfying the failure criterion) and point‐to‐surface constraint for opened points. The performance of the element is tested under mode I, mode II and mixed mode loading conditions.

Modeling Compression Failure after Low Velocity Impact on Laminated Composites Using Interface Elements

Low velocity impact damage can significantly reduce the residual strength of laminated composites. This kind of damage (mostly delaminations) is very dangerous for the structures because it is not apparent to the naked eye and, in some cases, it can reduce the compressive residual strength up to 60%. In this work, a numerical model for predicting the compression failure of laminated composites containing delamination caused by low velocity impact was developed. An interface finite element, previously developed by the authors, was used. This element is compatible with twenty-seven node isoparametric hexahedral elements and enables modeling the behavior of the damaged interface, taking into account a three-dimensional stress state, the interpenetration constraint and the propagation of delamination. In order to verify the numerical model, some experimental work was done. The experimental work, performed on carbon-epoxy (04, 904)5 and (904, 04), laminates, included low velocity impact tests using a drop weight testing machine, followed by X-Ray damage characterization and compression tests using a fixture system similar to IITRI system. The numerical and experimental results were compared and good agreement was obtained.

Fracture Mechanics Tests in Adhesively Bonded Joints: A Literature Review

Fracture mechanics characterization tests for adhesive joints are analyzed and reviewed in order to understand their advantages and disadvantages. Data reduction techniques for analytical methods are summarized to understand the improvements implemented in each test. Numerical approaches are also used complementing tests information. Both linear and non-linear methods to obtain the fracture energy release rate are presented. Pure mode I and mode II tests are described. Simple mixed-mode tests, varying only the specimen geometry, with limited mode-mixity are also presented. Performing a wider mode-mixity range requires sophisticated apparatus that are studied in detail. There is no general agreement about the test suitability for mixed-mode fracture assessment of adhesive joints. A universal test that can easily be performed and give accurate results is essential to optimize the expensive testing at the design stage.

Stress and failure analyses of scarf repaired CFRP laminates using a cohesive damage model

This study describes stress and failure analyses of tensile loaded repaired Carbon Fibre Reinforced Composite (CFRP) laminates, using scarf configuration. A numerical model including interface finite elements was used to obtain peel and shear-stress distributions in the directions tangent and normal to the scarf. These stresses were evaluated at several locations in the repair, namely in the middle of the adhesive, at interfaces between adhesive and patch, and between adhesive and parent material. Several scarf angle values were considered in the analysis. A cohesive mixed-mode damage model was also used to carry out the failure analysis, in order to assess the efficiency of the repairs, for different stacking sequences. A study was performed to evaluate the influence of the mechanical properties of the adhesive and parent laminate/adhesive and adhesive/patch interfaces on the strength and failure modes of the joint. It was concluded that the strengths of the adhesive and interfaces are more important than the fracture properties in the failure process of the repair. It was also verified that the strength of the repair increased exponentially with the scarf angle reduction.

Prediction of compressive strength of carbon–epoxy laminates containing delamination by using a mixed-mode damage model

Abstract It is well known that composite laminates are easily damaged by low-velocity impact. The internal delaminations can drastically reduce the compressive strength of laminates. In this study, a numerical analysis for predicting the residual compressive strength of delaminated plates is proposed. The delaminated interfaces are modelled by using interface elements connecting the three-dimensional solid elements modelling the composite layers. Delamination propagation is modelled by using a damage model based on the indirect use of fracture mechanics. Due to the complex stress state of the problem, a mixed-mode analysis including the three modes of fracture was considered. Experimental studies were performed on carbon–epoxy [04, 904]s and [904, 04]s laminates. They included low-velocity impact tests, followed by X-ray damage characterisation and compression tests. Good agreement between experimental and numerical analysis was obtained.