Peter Middendorf

Composite crash absorber for aircraft fuselage applications

A composite crash absorber element for potential use in z-struts of commercial aircraft fuselage structures was developed, which absorbs energy under crash loads by cutting the composite strut into stripes and crushing the material under bending. The design concept of this absorber element is described and the performance is evaluated experimentally in static, crash and fatigue test series on component and structural level under normal and oblique impact conditions. The physics of the energy absorption by high rate material fragmentation and delamination interactions are explained and numerical modelling methods in explicit finite element codes for the simulation of the crash absorber are assessed.

A Discrete Model for Simulation of Composites Plate Impact Including Coupled Intra- and Inter-ply Failure

Laminated composites can undergo complex damage mechanisms when subjected to transverse impact. For unidirectional laminates it is well recognized that delamination failure usually initiates via intra-ply shear cracks that run parallel to the fibres. These cracks extend to the interface of adjacent orthogonal plies, where they are either stopped, or propagate further as inter-ply delamination cracks. These mechanisms largely determine impact energy absorption and post-delamination bending stiffness of the laminate. Important load transfer mechanisms will occur that may lead to fibre failure and ultimate rupture of the laminate. In recent years most Finite Element (FE) models to predict delamination usually stack layers of ply elements with interface elements to represent inter-ply stiffness and treat possible delamination. The approach is computationally efficient and does give some estimate of delamination zones and damaged laminate bending stiffness. However, these models do not properly account for coupled intra-ply shear failure and delamination crack growth, and therefore cannot provide accurate results on crack initiation and propagation. An alternative discrete meso-scale FE model is presented that accounts for this coupling, which is validated against common delamination tests and impact delamination from the Compression After Impact (CAI) test. Ongoing research is using damage prediction from the CAI simulation as a basis for residual strength analysis, which will be the published in future work.

Experimental comparison of a macroscopic draping simulation for dry non-crimp fabric preforming on a complex geometry by means of optical measurement

Scope of the presented work is a detailed comparison of a macroscopic draping model with real fibre architecture on a complex non-crimp-fabric preform using a new robot-based optical measurement system. By means of a preliminary analytical process design approach, a preforming test centre is set up to manufacture dry non-crimp-fabric preforms. A variable blank holder setup is used to investigate the effect of different process parameters on the fibre architecture. The real fibre architecture of those preforms is captured by the optical measurement system, which generates a three-dimensional model containing information about the fibre orientation along the entire surface of the preform. The measured and calculated fiber orientations are then compared with the simulation results in a three-dimensional overlay file. The results show that the analytical approach is able to predict local hot spots with high shear angles on the preform. Macroscopic simulations show a higher sensitivity towards changes in blank holder pressure than reality and limit the approach to precisely predict fibre architecture parameters on complex geometries.

Detection of delamination onset in laser-cut carbon fiber transverse crack tension specimens using acoustic emission:

Numerous experimental studies have been made on cutting carbon fibers with lasers with the focus on productivity due to high cutting speeds. However, the laser-cutting process has an influence on the mechanical properties of the carbon fiber-reinforced plastic. This paper presents a test to determine the impact of thermal damage at the cutting edge. The initiation load for mode II delamination at the transverse crack tension test can be used to estimate the impact on the mechanical properties of thermal damage at the cutting edge. Detection of the initiation load is done via acoustic emission methods. Two different specimen geometries show a decrease of more than 40% of the initiation load for a CO2 continuous wave laser system with a large heat-affected zone compared to mechanically cut specimens.

An Integral Mesoscopic Material Characterization Approach

In several fields of engineering the automation of the CFRP production chain is a major issue. In this production chain the forming plays a key role, as the result of the forming influences everything in the chain from the infusion step until the part mechanics. To understand the influence of the material choice onto the forming process is a task followed by many scientists during the last 20 years. Basic tests for shear characterization like Picture Frame Test (PFT) and Bias Extension Test (BiasExt) were developed and used widely. This work deals with the comparison of the BiasExt to a fiber extraction test. The fiber extraction test is developed and used for the characterization of a woven and two non-crimp fabric material. The results are important for the process information and the judgment of primary deformation mechanisms. The tests are simulated for the unidirectional material in a mesoscopic approach and the results are compared in order to judge the capability of the mesoscopic simulation and its residual limitations.

Holistic and Consistent Design Process for Hollow Structures Based on Braided Textiles and RTM

The present paper elaborates a holistic and consistent design process for 2D braided composites in conjunction with Resin Transfer Moulding (RTM). These technologies allow a cost-effective production of composites due to their high degree of automation. Literature can be found that deals with specific tasks of the respective technologies but there is no work available that embraces the complete process chain. Therefore, an overall design process is developed within the present paper. It is based on a correlated conduction of sub-design processes for the braided preform, RTM-injection, mandrel plus mould and manufacturing. For each sub-process both, individual tasks and reasonable methods to accomplish them are presented. The information flow within the design process is specified and interdependences are illustrated. Composite designers will be equipped with an efficient set of tools because the respective methods regard the complexity of the part. The design process is applied for a demonstrator in a case study. The individual sub-design processes are accomplished exemplarily to judge about the feasibility of the presented work. For validation reasons, predicted braiding angles and fibre volume fractions are compared with measured ones and a filling and curing simulation based on PAM-RTM is checked against mould filling studies. Tool concepts for a RTM mould and mandrels that realise undercuts are tested. The individual process parameters for manufacturing are derived from previous design steps. Furthermore, the compatibility of the chosen fibre and matrix system is investigated based on pictures of a scanning electron microscope (SEM). The annual production volume of the demonstrator part is estimated based on these findings.

Identification of Forming Limits for Unidirectional Carbon Textiles in Reality and Mesoscopic Simulation

In several fields of engineering the use of carbon fibre reinforced material (CFRP) is increasing. Minimized weight due to CFRPs could lead to lower consumption of raw materials especially in the automotive area. The goal within the research project TC² is the decrease of costs and production time for composite materials. To achieve better performance to weight ratio and to get acceptable production conditions the draping of dry unidirectional textiles and a following RTM process is investigated. Due to the high degree of complexity of automotive structures the forming process is challenging. Gapping in the textile could appear at corners as well as wrinkling or flexion of the fibres. To be able to define the amount and direction of layers or patches it is necessary to know the limits of forming for unidirectional material and to be able to predict the behaviour of the textile during the forming process. For the definition of the process limits several draping strategies are performed on different corner blend geometries. The goal of that work is to define the critical gradient of the flange to get first failures such as wrinkling or gapping. It is also important to understand the influence of different draping strategies. Parallel to the experimental tests a mesoscopic simulation method using an approach with roving and sewing thread is developed and presented. It is able to predict the material behaviour in critical areas (gapping, wrinkling). Different Young’s moduli and failure criteria can be implemented for the two main directions as well as for the bending of the textile. A validation with the experimental results is performed with the aim to enable the prediction of the textile behaviour using simulation methods.

A mesoscopic approach for draping simulation of preforms manufactured by direct fibre placement

The draping of preforms made by automated fibre placement is a suitable way to generate complex, three-dimensional preforms. The absence of weaving or sewing yarns leads to a high tendency towards defects, such as gaps. To predict those defects a detailed simulation model of the material is necessary. This work deals with a method to describe the inter-ply friction of preforms that consists of carbon fibre yarns joined by a thermoplastic binder. Therefore, a friction model which is customised to the partial presence of molten binder is proposed. This model is used in a mesoscopic draping simulation and is validated by draping experiments.The draping of preforms made by automated fibre placement is a suitable way to generate complex, three-dimensional preforms. The absence of weaving or sewing yarns leads to a high tendency towards defects, such as gaps. To predict those defects a detailed simulation model of the material is necessary. This work deals with a method to describe the inter-ply friction of preforms that consists of carbon fibre yarns joined by a thermoplastic binder. Therefore, a friction model which is customised to the partial presence of molten binder is proposed. This model is used in a mesoscopic draping simulation and is validated by draping experiments.

ARENA2036 – DigitPro: Development of a virtual process chain

The demand for a reduction of weight in automotive application is increasing in several research and development projects. The reason for that are the decline of resources, strict laws for emissions and an increased awareness of natural environment. Fiber reinforced plastics (FRP) can be used to decrease the weight of automotive structures as load path directed material distribution is possible.

A novel textile characterisation approach using an embedded sensor system and segmented textile manipulation

This paper investigates the application of sensors on carbon fibre textiles for the purpose of textile characterisation and draping process optimisation. The objective is to analyse a textile’s condition during the draping operation and actively manipulate boundary conditions in order to create better preform qualities. Various realisations of textile integrated sensors are presented, focusing on the measurement of textile strain. Furthermore, a complex textile characterisation approach is presented where these sensors shall be implemented in.This paper investigates the application of sensors on carbon fibre textiles for the purpose of textile characterisation and draping process optimisation. The objective is to analyse a textile’s condition during the draping operation and actively manipulate boundary conditions in order to create better preform qualities. Various realisations of textile integrated sensors are presented, focusing on the measurement of textile strain. Furthermore, a complex textile characterisation approach is presented where these sensors shall be implemented in.