F inite element modelling of progressive damage in non-crimp 3D - - PowerPoint PPT Presentation

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F inite element modelling of progressive damage in non-crimp 3D - - PowerPoint PPT Presentation

Aug 30, 2023 132 likes •413 views

F inite element modelling of progressive damage in non-crimp 3D orthogonal weave and plain weave E -glass composites Stepan V. LOMOV, Dmitry S. IVANOV, Ignaas VERPOEST Department MTM, Katholieke Universiteit Leuven, Belgium Alexander E.

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3D Textiles Greenville 2009 1

F inite element modelling of progressive damage in non-crimp 3D

  • rthogonal

weave and plain weave E

  • glass

composites

Stepan V. LOMOV, Dmitry S. IVANOV, Ignaas VERPOEST Department MTM, Katholieke Universiteit Leuven, Belgium Alexander E. BOGDANOVICH 3Tex Inc, USA Kenta HAMADA, Tetsusei KURASHIKI, Masaru ZAKO Osaka University, Japan Mehmet KARAHAN Uludag University, Turkey

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3D Textiles Greenville 2009 2

C

  • ntents
  • 1. Introduction: Materials and experimental results
  • 2. FE models and progressive damage model
  • 3. Results of FE analysis and comparison with experiments
  • 4. Conclusions
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SLIDE 3

3D Textiles Greenville 2009 3

  • 1. Introduction
  • meso-FE analysis of textile composites
  • Materials: 3D non-crimp fabrics and plain weave laminate
  • Experimental results
  • 2. FE models and progressive damage model
  • 3. Results of FE analysis and comparison with experiments
  • 4. Conclusions
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SLIDE 4

3D Textiles Greenville 2009 4

meso-F E : R

  • ad map

Geometric modeller Geometry corrector Meshing Assign material properties Boundary conditions FE solver, postprocessor Homogenisation Damage analysis

N+1 N N+2

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3D Textiles Greenville 2009 5

SACOM , Visu a l SACO M M esh Tex W iseTex

WiseTex–MeshTex/S A C O M

State-of-the-art numerical tool for preparation of FE models and FE analysis of textile composites on meso-structural level Geometric modeller Geometry corrector Meshing Assign material properties Boundary conditions FE solver, postprocessor Homogenisation Damage analysis

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3D Textiles Greenville 2009 6

Internal structure of 3D and plain weave composites

Plain weave laminate

  • 1. Almost straight

yarns

  • 2. Slight crimp of

the fill caused by compaction in VARTM Crimped warp/weft, nested plies

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3D Textiles Greenville 2009 7

P arameters of 3D and plain woven fabric

2.76 Z-yarns per cm 2.64 Picks per cm 1470 layer 2,3 1470 layer 1,4 Fill (double yarns) 276 Z-yarns 1100 layer 2 2275 layer 1,3 Warp tex Yarns 48.9 VF, % 2.76 Ends (straight) per cm per layer 2.6 Thickness, mm 3255 Areal density, g/m2 1 ply Fabric and composite plate

3D – 96 (oz/sq.yrd) 2D – 24 (oz/sq.yrd)

6.19 Picks per cm 2275 Warp and weft tex Yarns 52.4 VF, % 5.08 Ends per cm 2.45 Thickness, mm 3260 Areal density, g/m2 4 ply Fabric and composite plate

4 plies: 0° /90° /90° /0° Warp : Fill : Z = 49% : 48% : 2%

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3D Textiles Greenville 2009 8

Q uasi static tension with acoustic emission and strain mapping

2D-24

100 200 300 400 500 0.5 1 1.5 2 2.5 3 3.5 strain, % stress, MPa 1.E+01 1.E+02 1.E+03 1.E+04 1.E+05 1.E+06 1.E+07 1.E+08 1.E+09 1.E+10 AE stress-strain AE events AE cumulative

1.E+02 1.E+03 1.E+04 1.E+05 1.E+06 1.E+07 1.E+08 1.E+09 0.2 0.4 0.6 0.8 1 strain, % AE energy

cumulative energy energy of events 0.E+00 5.E+03 1.E+04 0.2 0.4 0.6 0.8 1 strain, % AE energy 0.E+00 5.E+07 1.E+08 0.2 0.4 0.6 0.8 1 strain, % AE energy

1 2 a b c min 1 2

Displacement-controlled tension (Instron) Acoustic emission (Vallen) Strain-mapping (LIMESS)

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3D Textiles Greenville 2009 9

E xperimental results

Tension in warp/fill direction, normalised @VF=50%

100 200 300 400 500 600 0.5 1 1.5 2 2.5 3 3.5 strain, % stress, MPa

3D-96, warp 3D-96, fill 2D-24

3D non-crimp composites: damage initiation delayed 3D non-crimp composites: higher strength

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3D Textiles Greenville 2009 10

D amage development

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3D Textiles Greenville 2009 11

  • 1. Introduction
  • 2. FE models and progressive damage model
  • Geometrical models
  • Meshing
  • Progressive damage model
  • 3. Results of FE analysis and comparison with experiments
  • 4. Conclusions
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3D Textiles Greenville 2009 12

3D finite element model of 2D woven composite

One ply Mesh in the yarns Full mesh Clearance between yarns 0.005 mm Resin layer on the surface 0.005 mm VF 47.2% (WiseTex: 52.0%) Total elements 8512 Penetrating nodes corrected 1613 Max aspect ratio 1337 Max aspect ratio in yarns 64

W iseTex M esh Tex

Correct representation of measurable parameters:

  • areal density
  • thickness
  • verall fibre volume fraction
  • ends/picks count
  • yarn dimensions

Simplifications:

  • modelling of one ply with periodic

BC in the thickness direction

  • unbalanced ply vs balanced laminate
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SLIDE 13

3D Textiles Greenville 2009 13

3D finite element model of 3D woven composite

Mesh in the yarns Full mesh Clearance between yarns 0.005 mm Resin layer on the surface 0.005 mm VF 43.7% (WiseTex: 48.9%) Total elements 20768 Penetrating nodes corrected 3000 Max aspect ratio 469 Max aspect ratio in yarns 60

W iseTex M esh Tex

Correct representation of measurable parameters:

  • areal density
  • thickness
  • verall fibre volume fraction
  • ends/picks count
  • yarn dimensions

Simplifications:

  • elliptical shape of yarn cross-sections
  • constant dimensions of Z-yarns
  • VF inside yarns up to 90% (Z-yarns)
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SLIDE 14

3D Textiles Greenville 2009 14

D amage model (built-in in S A C O M) –1

Damage initiation: Hoffmann

2 9 2 8 2 7 6 5 4 2 3 2 2 2 1

) ( ) ( ) (

LT ZL TZ Z T L T L L Z Z T

C C C C C C C C C F

  • 2

9 2 8 2 7 6 5 4 3 2 1

1 , 1 , 1 1 1 , 1 1 , 1 1 1 1 1 2 1 1 1 1 2 1 1 1 1 2 1

s LT s ZL s TZ c Z t Z c T t T c L t L c Z t Z c T t T c L t L c T t T c L t L c Z t Z c L t L c Z t Z c T t T

F C F C F C F F C F F C F F C F F F F F F C F F F F F F C F F F F F F C

Definition of the damage mode

L T Z

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3D Textiles Greenville 2009 15

D amage model (built-in in S A C O M) –2

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3D Textiles Greenville 2009 16

U D strength parameters

88 shear 112 Compression 76 tensile Matrix 70 TZ 70 89 70 LT 140 128 140 T, compr 40 39 40 T, tensile 620 620 620 L, compression 1725 1380 1080 1020 L, tensile Corrected (L) for 75% and accepted for calculations Hybon’ data [6], VF=55% [1], VF=60% UD

[1] "Composites Engineering Handbook" (P.K. Mallick, Ed.), Marcel Dekker, Inc., New York, 1997 (Table 1) [2] "Engineering Mechanics of Composite Materials" by I.M. Daniel and O. Ishai, Oxford University Press, New York - Oxford, 1994 (Table 2.6)

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3D Textiles Greenville 2009 17

  • 1. Introduction
  • 2. FE models and progressive damage model
  • 3. Results of FE analysis and comparison with experiments
  • Tensile diagram
  • Strength
  • Damage initiation
  • Damage propagation and damage modes
  • 4. Conclusions
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3D Textiles Greenville 2009 18

E lastic properties: correct!

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3D Textiles Greenville 2009 19

0.0005 0.001 0.0015 0.002 0.0025 0.003 500

F E vsstrain map. xx.Tension in warp direction, < xx > = 0.1 %

FE LIMESS FE: z-periodicity Digital image correlation:

  • Free surface
  • segment 29x29 pix
  • step 5x5 pix
  • strain calculation 5x5 filter
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3D Textiles Greenville 2009 20

3D MO S A IC vsstrain map. xx.Tension in warp direction, < xx > = 0.2 %

Free surface Digital image correlation:

  • segment 29x29 pix
  • step 5 pix
  • strain calculation 5x5 filter
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SLIDE 21

3D Textiles Greenville 2009 21

Tensile diagrams, 2D composite

  • correct modelling of degradation
  • f stiffness
  • reasonable evaluation of damage

initiation threshold

  • qualitative representation of

intensity of damage

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SLIDE 22

3D Textiles Greenville 2009 22

Tensile diagrams, 3D composite

  • correct modelling of degradation
  • f stiffness
  • reasonable evaluation of damage

initiation threshold

  • qualitative representation of

intensity of damage

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SLIDE 23

3D Textiles Greenville 2009 23

S trength, 2D and 3D composites

2D 3D 1. The calculations for one unit cell do not represent stochastic failure of the full sample. 2. Longitudinal strength value for glass fibres and the strength of the impregnated fibre bundles, assumed in the failure criterion, is based on the fibre manufacturer’s data sheet and may not reflect the actual strength of the fibres after textile processing. 3. The damage model does not include influence of delamination and splitting, evident in 2D composites at the late stage of deformation

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SLIDE 24

3D Textiles Greenville 2009 24

P rogressive damage, 2D composite

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SLIDE 25

3D Textiles Greenville 2009 25

P rogressive damage, 3D composite

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SLIDE 26

3D Textiles Greenville 2009 26

  • 1. Introduction
  • 2. FE models and progressive damage model
  • 3. Results of FE analysis and comparison with experiments
  • 4. Conclusions
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3D Textiles Greenville 2009 27

C

  • nclusions

1. The overall behaviour of the material (initial elastic modules and Poisson coefficients, stress-strain diagram, stiffness deterioration) can be predicted with meso-FE analysis with acceptable closeness to the experimental data. 2. Predictions of the strength and ultimate strain are not satisfactory, presumably due to unaccounted for stochastic nature of these parameters, variations of the strength of glass fibres in textile processing and local delamination damage mode. 3. Predictions of damage initiation threshold are sensitive to the choice of the input data (transverse and shear strength of the UD material), but lie in the experimentally observed range of damage initiation loads 4. Damage patterns inside the unit cell are described qualitatively well with the stiffness degradation scheme; the model adequately differentiates the transverse, shear and fibre failure damage modes.