damage tolerance and notch sensitivity of composite ... · sandwich fracture mechanics •...
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Damage Tolerance and Notch Sensitivity of Composite
Sandwich Structures
Dan AdamsMarcus StanfieldBrad KuramotoMartin Raming
University of Utah
JAMS 2019 Technical ReviewMay 22-23, 2019
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FAA Sponsored Project Information
• Principal Investigators: Dr. Dan AdamsDr. Mike Czabaj
• Graduate Student Researchers: Martin RamingBrad KuramotoMarcus Stanfield
• Primary Collaborators:Boeing (Charles Park), Hexcel (Lance Smith)Materials Sciences CorporationASTM D30 (Composites)
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Sandwich Fracture Mechanics• Development of standardized test methods
for facesheet/core disbond growth• Building block approach for assessment of
disbond growth in sandwich structuresSandwich Damage Tolerance• Assessment of predictive capabilities for
damage formation and growth • Development of standardized test methods
for damage toleranceSandwich Notch Sensitivity• Assessment of predictive capabilities for
sandwich composite notch sensitivity• Development of standardized test
methods for notch sensitivity
Project Overview:Primary Research Emphases
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Status Update:Mode I Sandwich Fracture Mechanics Test Method
• Completed three rounds of ASTM balloting; fourth upcoming
• Recent changes:– Mode mixity: “Mode I dominant” – Acceptable disbond location:
within top one-fourth of core• Discussion of remaining issues:
– Procedure for disbond initiation toughness
– Accelerated loading rate to produce acceptable disbondgrowth rate and test time
Standardization of Single Cantilever Beam (SCB) Test
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Test paused
0
5
10
15
20
25
0 0.5 1 1.5
Load
[lbf
]
Extension [in]
Current SCB Discussion Item:Pausing Test for Crack Tip Measurement
• Current procedure leads to long test times‒ 5-30 minutes without initiation
toughness measurements‒ 10-60 minutes with initiation
toughness measurements
• Accelerated loading rate requires pausing for crack length measurement
• Minimal crack growth observed while paused under load
• Modified procedure under review by Sandwich Disbond Task Group
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• Follow-on Standard Practice to existing SCB test
• Several previous individual efforts within CMH-17 Sandwich DisbondTask Group
• Draft test procedure identified for upcoming round robin testing
Recent Focus:Single Cantilever Beam (SCB) Fatigue Test
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• Sandwich specimens to be fabricated at University of Utah and distributed to round robin participants– IM7/8552 woven fabric prepreg facesheets– Nomex honeycomb core– Metlbond 1515-4 film adhesive
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• Enlarged/simplified version of test fixture used for composite laminates (ASTM D6671)
• High percentage Mode II possible (up to ~80%)
• Round-robin testing exercise planned• Draft ASTM standard in progress• Collaboration with DTU (C. Berggreen)
Recent Focus:Sandwich Mixed Mode Bend (MMB) Test
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Status Update:Mode II Separated End-Notched Flexure (S-ENF) Test
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• Modified three-point flexure test • Use of tensioned wire to achieve
facesheet/core separation• No core removal required• Adjustable wire height and span• High % Mode II (>80%) for all
sandwich configurations studied• Cell buckling at crack tip with no
crack growth for some honeycomb core configurations
• Under further investigation with FAU collaborators (L. Carlsson)
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Sandwich Fracture Mechanics• Development of standardized test methods
for facesheet/core disbond growth• Building block approach for assessment of
disbond growth in sandwich structuresSandwich Damage Tolerance• Assessment of predictive capabilities for
damage formation and growth • Development of standardized test methods
for damage toleranceSandwich Notch Sensitivity• Assessment of predictive capabilities for
sandwich composite notch sensitivity• Development of standardized test
methods for notch sensitivity
Project Overview:Primary Research Emphases
9
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Damage Tolerance Test MethodsFor Sandwich Composites
In the initial stages of ASTM standardization
• Preferred damage tolerance test method for laminates
• High interest level for sandwich composites
• Second ASTM balloting in Summer 2019
• Constant bending moment and zero shear in damaged section
• Damaged facesheet can be loaded in compression or tension
• Initial ASTM ballot submission in Summer 2019
Edgewise Compression After Impact
Four-Point Flexure After Impact
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Damage Progression in Sandwich Composites:Testing to Evaluate of Predictive Capabilities
• Damage progression in facesheets– Interlaminar delamination (Mode I and II)– Laminate tension (±45 layup)– Open-hole tension– Open-hole compression
• Damage progression in core– Flatwise compression– Flatwise shear
• Damage progression in sandwich composites– Sandwich interface disbond (Mode I and II)– Sandwich open-hole shear– Sandwich open-hole flexure– Sandwich open-hole compression
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• User-defined nonlinear material model (UMAT) for ABAQUS
• Developed by Materials Sciences Corp.• Stiffness degradation based
progressive damage model– Bilinear stiffness response used
to model material damaged state– “Built in” laminated plate theory for
elements– Lamina level stiffness degradation– Max. stress, max. strain or Hashin
failure criteria for damage onset
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Progressive Damage Analysis of Sandwich CompositesABAQUS with NDBILIN
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Progressive Damage Analysis of Sandwich CompositesB-Spline Method (BSAM):
• Stand-alone software• Developed by AFRL, UDRI, UTA• Discrete damage modeled using
Regularized Extended Finite Element Method (Rx-FEM)– Matrix Cracking
Multiple failure criteria for damage onset Damage propagation using cohesive zone
method
– Delamination using cohesive zone method
– Fiber failure using Critical Failure Volume or CDM
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Damage Progression in Facesheets:Analysis of ±45 Laminates in Tension
• Simulation of unnotched and open-hole tension testing• IM7/8552 carbon/epoxy, [45/-45]2S laminates • Matrix shear modulus, strength and damage parameters
calibrated using measured stress-strain behavior– NDBILIN: bilinear response– BSAM: non-linear response
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Damage Progression in Facesheets:0/90 Cross-ply Open-Hole Tension
• [0/90/0]T laminate representing sandwich facesheet
• NDBILIN predicts notch sensitivity• BSAM predicts notch insensitive
(Less than 4% error)• BSAM requires fine mesh for a
converged solution0
2000
4000
6000
8000
0 0.005 0.01 0.015
Load
(lbf
)
Strain (in/in)
OHT [0/90/0]T
TestNDBILINBSAM
X-Ray CT NDBILIN
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BSAM
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Damage Progression in Core:Flatwise Compression/Shear
• Honeycomb core loaded until core collapse in both compression and shear
• NDBILIN parameters fit to stress vs strain curves
• Used to predict open-hole shear test results
0
500
1000
1500
2000
0 0.025 0.05 0.075
Stre
ss (p
si)
Strain (in/in)
Compression
TestNDBILIN
020406080
100120
0 0.05 0.1 0.15 0.2 0.25
Stre
ss (p
si)
Strain (in/in)
Shear
NDBILINTest
Flatwise Shear Test
Compression Test
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Sandwich Open Hole Compression
Test Method Development:Notch Sensitivity of Sandwich Composites
• Open Hole Compression and Open Hole Flexure test method development for ASTM standardization (Draft standards in progress)
• Used for assessment of progressive damage analysis methods
• Open Hole Shear test designed to focus on progressive core damage during three-point flexure loading
Sandwich Open Hole Flexure
Sandwich Open Hole Shear
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• Unnotched and notched four-point flexure testing
• Core modeled with NDBILIN• Slight over prediction of max load in
open hole shear test
0
50
100
150
200
250
300
350
400
0 0.1 0.2 0.3
Load
(lbf
)
Extension (in)
UnnotchedNotchedNDBILIN
Sandwich Open-Hole Shear Failure
Model Deformation
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Damage Progression in Sandwich Composites:Analysis of Open Hole Shear Tests
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• Calibration of interfacial cohesive zone– Mode I Sandwich SCB
Damage Progression in Sandwich Composites:Analysis of Facesheet/Core Disbond
Single Cantilever Beam Test
SCB Model DisplacementsLoad vs Displacement Data
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• 90% load X-ray CT shows minimal damage progression
• NDBILIN overpredicting damage and under predicting failure load
DIC Strain NDBILIN Damage Prediction
X-Ray CT(Courtesy of Southwest Research Institute)
Compression Strength Comparison
0
20
40
60
80
100
1 inch thick core
Stre
ngth
(ksi
)
Notched
FEM
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Damage Progression in Sandwich Composites:Analysis of Open-Hole Flexure Test
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• Out-of-plane displacements observed in DIC measurements• First mode facesheet buckling observed• Global buckling due to failure on non-DIC facesheet• Deformation caused by post failure eccentric loading
Measured out-of-plane deformationIdealized Failure Out-of-plane deformations
FEM DIC
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Damage Progression in Sandwich Composites:Analysis of Open-Hole Compression
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BENEFITS TO AVIATION• Standardized test methods to assess facesheet/core
disbond growth in sandwich composites
• Evaluation of current numerical capabilities for predicting notch sensitivity and damage tolerance of sandwich composites
• Standardized test methods to assess notch sensitivity in sandwich composites
• Standardized test methods to assess damage tolerance in sandwich composites
• Dissemination of research results through FAA technical reports and conference/journal publications
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