Wim Van Paepegem

Fatigue damage modeling of fibre-reinforced composite materials: Review

This paper presents a review of the major fatigue models and life time prediction methodologies for fibrereinforced polymer composites, subjected to fatigue loadings. In this review, the fatigue models have been classified in three major categories: fatigue life models, which do not take into account the actual degradation mechanisms but use S-N curves or Goodman-type diagrams and introduce some sort of fatigue failure criterion; phenomenological models for residual stiffness/strength; and finally progressive damage models which use one or more damage variables related to measurable manifestations of damage (transverse matrix cracks, delamination size). Although this review does not pretend to be exhaustive, the most important models proposed during the last decades have been included, as well as the relevant equations upon which the respective models are based.

Improved Newton–Raphson digital image correlation method for full-field displacement and strain calculation

The two-dimensional in-plane displacement and strain calculation problem through digital image processing methods has been studied extensively in the past three decades. Out of the various algorithms developed, the Newton-Raphson partial differential correction method performs the best quality wise and is the most widely used in practical applications despite its higher computational cost. The work presented in this paper improves the original algorithm by including adaptive spatial regularization in the minimization process used to obtain the motion data. Results indicate improvements in the strain accuracy for both small and large strains. The improvements become even more significant when employing small displacement and strain window sizes, making the new method highly suitable for situations where the underlying strain data presents both slow and fast spatial variations or contains highly localized discontinuities.

Damage-Resistant Composites Using Electrospun Nanofibers: A Multiscale Analysis of the Toughening Mechanisms

Today, fiber-reinforced polymer composites are a standard material in applications where a high stiffness and strength are required at minimal weight, such as aerospace structures, ultralight vehicles, or even flywheels for highly efficient power storage systems. Although fiber-reinforced polymer composites show many advantages compared to other materials, delamination between reinforcing plies remains a major problem limiting further breakthrough. Traditional solutions that have been proposed to toughen the interlaminar region between reinforcing plies have already reached their limit or have important disadvantages such as a high cost or the need for adapted production processes. Recently, electrospun nanofibers have been suggested as a more viable interlaminar toughening method. Although the expected benefits are numerous, the research on composite laminates enhanced with electrospun nanofibrous veils is still very limited. The work that has been done so far is almost exclusively focused on interlaminar fracture toughness tests with different kinds of nanofibers, where typically a trial and error approach has been used. A thorough understanding of the micromechanical fracture mechanisms and the parameters to obtain toughened composites has not been reported as of yet, but it is crucial to advance the research and design highly damage-resistant composites. This article provides such insight by analyzing the nanofiber toughening effect on three different levels for several nanofiber types. Only by combining the results from different levels, a thorough understanding can be obtained. These levels correspond to the hierarchical nature of a composite: the laminate, the interlaminar region, and the matrix resin. It is found that each level corresponds to certain mechanisms that result in a toughening effect. The bridging of microcracks by electrospun nanofibers is the main toughening mechanism resulting in damage resistance. Nevertheless, the way in which the nanofiber bridging mechanism expresses itself is different for each scale and dependent on parameters linked to a certain scale. The multiscale analysis of the toughening mechanisms reported in this paper is therefore crucial for understanding the behavior of nanofiber toughened composites, and as such allows for designing novel, damage-resistant, nanofiber-toughened materials.

Pixel-level robust digital image correlation

Digital Image Correlation (DIC) is a well-established non-contact optical metrology method. It employs digital image analysis to extract the full-field displacements and strains that occur in objects subjected to external stresses. Despite recent DIC progress, many problematic areas which greatly affect accuracy and that can seldomly be avoided, received very little attention. Problems posed by the presence of sharp displacement discontinuities, reflections, object borders or edges can be linked to the analysed objects properties and deformation. Other problematic areas, such as image noise, localized reflections or shadows are related more to the image acquisition process. This paper proposes a new subset-based pixel-level robust DIC method for in-plane displacement measurement which addresses all of these problems in a straightforward and unified approach, significantly improving DIC measurement accuracy compared to classic approaches. The proposed approach minimizes a robust energy functional which adaptively weighs pixel differences in the motion estimation process. The aim is to limit the negative influence of pixels that present erroneous or inconsistent motions by enforcing local motion consistency. The proposed method is compared to the classic Newton-Raphson DIC method in terms of displacement accuracy in three experiments. The first experiment is numerical and presents three combined problems: sharp displacement discontinuities, missing image information and image noise. The second experiment is a real experiment in which a plastic specimen is developing a lateral crack due to the application of uniaxial stress. The region around the crack presents both reflections that saturate the image intensity levels leading to missing image information, as well as sharp motion discontinuities due to the plastic film rupturing. The third experiment compares the proposed and classic DIC approaches with generic computer vision optical flow methods using images from the popular Middlebury optical flow evaluation dataset. Results in all experiments clearly show the proposed methods improved measurement accuracy with respect to the classic approach considering the challenging conditions. Furthermore, in image areas where the classic approach completely fails to recover motion due to severe image de-correlation, the proposed method provides reliable results.

A progressive damage model of textile composites on meso-scale using finite element method: static damage analysis

A meso-scale finite element model for static damage in textile composites was established. The impregnated yarn is taken as homogeneous and transverse isotropic material, whose mechanical properties are calculated using Chamis’ equations. The damage modes are determined by using the Tsai-Wu criterion and additional criteria. The Murakami damage tensor is used to calculate the post-damage stiffness matrix. The model has been validated using plain weave and twill weave carbon–epoxy composites. The initiation of inter-fiber matrix cracks and fiber rupture were analyzed using this meso-FE model.

Improved accuracy in the determination of flexural rigidity of textile fabrics by the Peirce cantilever test (ASTM D1388)

Within the field of composite manufacturing simulations, it is well known that the bending behavior of fabrics and prepregs has a significant influence on the drapeability and final geometry of a composite part. Due to sliding between reinforcements within a fabric, the bending properties cannot be determined from in-plane properties and a separate test is required. The Peirce cantilever test represents a popular way of determining the flexural rigidity for these materials, and is the preferred method in the ASTM D1388 standard. This work illustrates the severe inaccuracies (up to 72% error) in the current ASTM D1388 standard as well as the original formulation by Peirce, caused by ignoring higher-order effects. A modified approach accounting for higher-order effects and yielding significantly improved accuracy is presented. The method is validated using finite element simulations and experimental testing. Since no independent tests other than the ASTM D1388 standard are available to determine the bending stiffness of fabric materials, experimental validation is performed on an isotropic, homogeneous Upilex-50S foil for which the flexural rigidity and tensile stiffness are related. The flexural rigidity and elastic modulus are determined through both the cantilever test (ASTM D1388) and tensile testing. The results show that the proposed method measures an elastic modulus close to that determined through tensile testing (within 1%), while both the Peirce formulation (+18%) and ASTM standard (+72%) over-estimate the elastic modulus. The proposed methodology allows for a more accurate determination of flexural rigidity, and enables the more accurate simulation of composite forming processes.

Finite element modelling and experimental study of oblique soccer ball bounce

Abstract In this study, we develop a finite element model to examine the oblique soccer ball bounce. A careful simulation of the interaction between the ball membrane and air pressure in the ball makes the model more realistic than analytical models, and helps us to conduct an accurate study on the effect of different parameters on a bouncing ball. This finite element model includes a surface-based fluid cavity to model the mechanical response between the ball carcass and the internal air of the ball. An experimental set-up was devised to study the bounce of the ball in game-relevant impact conditions. Ball speed, angle, and spin were measured before and after the bounce, as well as ball deformation and the forces during the impact. The finite element model has been validated with three different sets of data, and the results demonstrate that the finite element model reported here is a valuable tool for the study of ball bounce. After validation of the model, the effect of the friction coefficient on soccer ball bounce was studied numerically. Simulation results show that increasing the friction coefficient may result in reversal of the horizontal impact force.

Sensor design for outdoor racing bicycle field testing for human vibration comfort evaluation

This paper is concerned with the vibrational comfort evaluation of the cyclist when cycling a rough surface. Outdoor comfort tests have so far only been done through instrumenting the bicycle with accelerometers. This work instruments a racing bicycle with custom-made contact force sensors and velocity sensors to acquire human comfort through the absorbed power method. Comfort evaluation is assessed at the hand–arm and seat interface of the cyclist with the bicycle. By means of careful finite-element analysis for designing the force gauges at the handlebar and the seat combined with precise calibration of both force and velocity sensors, all sensors have proven to work properly. Initial field tests are focused on the proper functioning of the designed sensors and their suitability for vibration comfort measurements. Tests on a cobblestone road reveal that the outcome of the absorbed power values is within the same range as those from laboratory tests found in the literature. This sensor design approach for outdoor testing with racing bicycles may give a new interpretation on evaluating the cyclists comfort since the vibrational load is not only quantified in terms of acceleration but also in terms of force and velocity at the bicycle–cyclist contact points.

Pitfalls in the experimental recording of ultrasonic (backscatter) polar scans for material characterization

The ultrasonic polar scan (UPS), either in transmission, reflection or backscatter mode, is a promising non-destructive testing technique for the characterization of composites, providing information about the mechanical anisotropy, the viscoelastic damping, the surface roughness, and more. At present, the technique is merely being used for qualitative purposes. The limited quantitative exploration and use of the technique can be primarily ascribed to limitations of current theoretical models as well as the difficulty to perform accurate, and more importantly, reproducible UPS experiments. Over the last years, we have identified several potential pitfalls in the experimental implementation of the technique which severely deteriorate the accurateness and reproducibility of a UPS. In this paper, we make an inventory of the most important difficulties, illustrate each of them by a real experiment and present a feasible mediation, either numerical or experimental in nature. Once the experimental set-up is fine-tuned to overcome these pitfalls, it is expected that the recording of high-level UPS experiments, in combination with numerical computations, will facilitate the technique to become a fully quantitative non-destructive characterization method.

Fatigue of Ti6Al4V Structural Health Monitoring Systems Produced by Selective Laser Melting

Selective laser melting (SLM) is an additive manufacturing (AM) process which is used for producing metallic components. Currently, the integrity of components produced by SLM is in need of improvement due to residual stresses and unknown fracture behavior. Titanium alloys produced by AM are capable candidates for applications in aerospace and industrial fields due to their fracture resistance, fatigue behavior and corrosion resistance. On the other hand, structural health monitoring (SHM) system technologies are promising and requested from the industry. SHM systems can monitor the integrity of a structure and during the last decades the research has primarily been influenced by bionic engineering. In that aspect a new philosophy for SHM has been developed: the so-called effective structural health monitoring (eSHM) system. The current system uses the design freedom provided by AM. The working principle of the system is based on crack detection by means of a network of capillaries that are integrated in a structure. The main objective of this research is to evaluate the functionality of Ti6Al4V produced by the SLM process in the novel SHM system and to confirm that the eSHM system can successfully detect cracks in SLM components. In this study four-point bending fatigue tests on Ti6Al4V SLM specimens with an integrated SHM system were conducted. Fractographic analysis was performed after the final failure, while finite element simulations were used in order to determine the stress distribution in the capillary region and on the component. It was proven that the SHM system does not influence the crack initiation behavior during fatigue. The results highlight the effectiveness of the eSHM on SLM components, which can potentially be used by industrial and aerospace applications.