low velocity impact performance analysis of fiber

Trans. JSASS Aerospace Tech. JapanVol. 12, No. ists29, pp. Pc_35-Pc_41, 2014

Original Paper

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Copyright© 2014 by the Japan Society for Aeronautical and Space Sciences and ISTS. All rights reserved.

Low Velocity Impact Performance Analysis of Fiber Composite Structure Embedded with Shape Memory Alloy

By Ying-Chih LIN 1), Yu-Liang CHEN 2) and Hung-Wen CHEN 3)

1) School of Defense Science, Chung Cheng Institute of Technology, National Defense University, Taiwan, ROC

2) Department of Power Vehicle and Systems Engineering, Chung Cheng Institute of Technology, National Defense University, Taiwan, ROC 3) Chung-San Institute of Sciences and Technology, Taiwan, ROC

(Received June 19th, 2013)

Low velocity impact performance analysis of fiber composite structure embedded with SMA was investigated.

And, the energy-absorption of the structure due to tensile, shear, bending, and delamination effects was studied. In this study, Ballistic test is used to explore performances of fiber composite structure embedded with SMA under a low velocity impact. 9mm Full Metal Jacket (FMJ) ammunition is used as projectile and 200 mm rectangular composite plate is used as target sample in this test. And, the control factors are number and arrangement of SMA material and thickness of the test samples. Taguchi method and ANOVA analysis method are used to explore the relevance and significance of each parameter to the energy absorption of the structure in this article. Furthermore, a multiple regression model was developed to fit the experimental data and to predict the energy absorption in changes of parameters effectively. Finally, the best combination of parameters used to resist a low velocity impact was obtained and discussed. The results reveal that the best combination of parameters enhances 19% of the energy absorption of the structure and SMA provides 18.47% contribution significantly.

Key Words: Shape Memory Alloys, Impact, Composite Structures, Multiple Regression

Nomenclature V : velocity E : energy absorption D : diameter E : Young's modulus : poisson's ratio : density

Wg : weight ud : unidirection c : crossover

Subscripts i : initial t : total 1. Introduction The high cost of production and poor resistance to damage have often limited the use of fibre-reinforced composite structures in the aerospace, marine and mass-transport industries. Due to the lack of through-the-thickness reinforcement, composite materials possess a poor resistance to through-the-thickness impact loading. Impact damage is one of the main problems. In particular, aerospace structures are often subjected to low velocity impacts which result in delamination, indentation or outright failure.

There are a number of solutions to improve impact resistance and damage of composite materials, such as fibre toughening, matrix toughening, interface toughening, through-the-thickness reinforcements, and selective interlayers and hybrids.

Advanced structural materials with shape memory alloy (SMA) wires have attracted many users nowadays, because of their potential uses: performance enhancement, shape control, damage tolerance, vibration suppression and self-repair1).

One of the possible solution to reduce impact damage in composite structures is to embed the SMA wires inside the polymer composites due to their superelastic behaviour allowing remarkably high strain to-failure and recoverable strain and their capability to generate recovery tensile stresses and hence reduce the deflections and the in-plane strains and stresses of the structure.

Smart materials can present an attractive tool for reducing deflections and stresses in the structures subjected to a low-velocity impact. In particular, SMA can generate significant tensile stresses. The necessary effect can be achieved if SMA fibers are embedded within a composite material resulting in a hybrid smart composite.

This paper presented an approach to the problem of optimum design of composite plates subjected to low-velocity impact.

Victor Birman et al. 2) investigated the deflections and stresses reduced by employing pre-strained shape memory alloy (SMA) fibers which are in the martensitic phase. However, due to a constraint, the contraction is either completely prevented or reduced resulting in significant tensile recovery stresses. It was shown that an application of SMA fibers can significantly reduce deflections and stresses.

S.M.R. Khalili 3-5) investigated the first-order shear deformation theory as well as the Fourier series method utilized to solve the dynamic governing equations of the hybrid composite plate analytically. The interaction between the impactor and the plate was modeled with the help of two

Trans. JSASS Aerospace Tech. Japan Vol. 12, No. ists29 (2014)

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degrees-of-freedom system, consisting of springs-masses. Choi’s linearized Hertzian contact model was used in the impact analysis of the laminated hybrid composite plate. The stiffness of the composite structures was classified into two new groups: contact stiffness in the improved Hertzian contact law and bending-shear stiffness. The procedure named smart stiffening procedure (SSP) was used to improve the impact resistance of the composite structures. It was seen that by using of the SSP, the mechanical characteristics of the structure could be improved the most. At the same time, It was studied that some of the important geometrical and physical parameters like the SMA volume fraction, orientation of composite medium fibers, impactor mass, impactor velocity, and length-to-thickness ratio of the plate (a/h ratio) are important factors affecting the impact process and the design of structures. Subsequently, a verified strict model for smart composite plate deflection was studied and developed, which embedded with the SMA wires, using response surface method (RSM). The results indicated that the volume fraction is a important factor affecting the optimization and the design process of the structures.

Yigit et al. 6) studied the low velocity impact response of composite plates by using dimensional analysis and lumped-parameter models. For a given impact event, it was shown that the non-dimensional parameters can be obtained by analytical, computational or experimental methods. It was shown that these simple models provide very good approximations of the impact response for a pre-determined wide range of impact parameters. Many studies have shown that shape memory alloy wires can absorb a lot of the energy during the impact due to their superelastic and hysteretic behavior. Aurrekoetxea et al.’s 7) study of low-velocity impact properties of shape memory alloy (SMA) wires and carbon fiber reinforced polyester (butylenes terephthalate) obtained by resin transfer molding were characterized. SMA has a positive effect on the maximum absorbed energy, since the maximum allowable load is higher. The contribution of the SMA wires to the higher impact performance of the hybrid composite is suggested to be due to their energy absorbing capability, and also to the high reversible force that acts as a healing force. Zheng et al. 8) investigated actuating ability and reliability of SMA hybrid composites. Results showed that by selecting small hysteresis SMA such as TiNiCu alloy, SMA hybrid composites have a linear stress–temperature behavior, which is relatively easy to control.

Meo et al. 9-10) investigated the impact damage behavior of carbon fiber/epoxy composite plates embedded with superelastic shape memory alloys wires. The results showed that for low velocity impact, embedding SMA wires into composites increases the damage resistance of the composites when compared to conventional composites structures. In 2013, he has given a review of shape memory alloy hybrid composites for improved impact properties for aeronautical applications. The results showed that for low velocity impact, embedding SMA wires into a fabric layer of the composite laminate placed in the middle plane of the laminate can improve impact resistance capability. In fact, for some cases, an improvement in the damage resistance and ductility of

composites structures was observed. It was also found the clear increase of the composites toughness and higher energy levels of absorbed energy before failure. In the present research, effect of low velocity impact upon the multilayered laminated smart composite plates was developed. The effect of using SMA wires with some of the parameters such as the volume fraction of SMA wires, the mass and the velocity of the impactor in a constant energy level, the orientation of the SMA wires and thickness of the composite plate on the impact influence of smart hybrid composite plate was studied in detail. 2. Experimental Setup and Procedure

2.1. Materials The superelastic SMA wires (0.6 mm diameter) used in this work are a commercially available NiTi alloy, nominal composition 55.99 at.% Ni balanced with Ti, production of Japan. The Spectra fiber reinforced laminates were manufactured heated to 120 °C and 70 kg/m2 after 30 min. The Kevlar fiber reinforced laminates were manufactured heated to 160 °C and 70 kg/m2 after 30 min. Spectra and Kevlar 29 prepreg fiber was purchased from HCG corporation in Taiwan.

Standard 8.07 g Full Metal Jacket (FMJ) projectile (round nose lead with a copper jacket) typically used in a 9mm handguns were used (Fig.1). The projectile had a weight variance less than 0.74% (± .06 g) and the properties of projectile are shown in Table 1.

Fig. 1. Full Metal Jacket (FMJ) projectile.

Table 1. Geometrical and material properties of the hybrid composite plate and the impactor. Geometrical properties of the SMA hybrid composite Boundary conditions All clamped Length = width 200mm Lay-up [(0/90)5]s [(0/90)7]s Properties of the impactor E 105 GPa D 9mm 0.346 Wg 8.07g 9 g/cm3 Vi 300~450m/s

2.2. Geometry of the plate and projectile

The impact tests were carried out on panels with dimensions of 200 mm long and 200 mm wide. The stacking arrangement of the plies was [(0/90)5]s or[(0/90)7]s. The diameter of the SMA used is 0.6 mm, and they were inserted

Y.-C. LIN et al.: Impact Performance Analysis of Shape Memory Alloy Composite Plate using Taguchi Method

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in the longitudinal and transverse direction within the plate. Two different implementations of SMA wires in the composite were studied. The first was 4 wires as shown in Fig. 2. The number of wires through the thickness and lamination sequence of hybrid samples is in Table 2.

The SMA wires were located symmetric to the central line of the sample, each with 35 mm to that line. The initial velocity of the impactor was 300~450 m/s, inducing impact energy level of respectively 400~ 800 J. The experimental impact tests were carried out using a 9 mm handgun. In a typical impact event, energy is absorbed by a material through elastic deformation, plastic deformation of failure mechanisms.

Fig. 2. Wires integration in the plies for a 2 by 2 by 2 configuration. 2.3. Impact testing

According to5.3 ballistic resistance test of 5.test methods of NIJ Standard 0108.01 for ballistic impact testing is placed the velocity measure screen 2 and 3 m, respectively from the muzzle of the test weapon as shown in Figure 1, and arrange them so that they define planes perpendicular to the line of flight of the bullet. Measure the distance between them with an accuracy of 1.0 mm. Use the time of flight and distance measurements to calculate the velocity of each test round.

The experimental setup was created according to guidelines given in the NIJ standard, as shown in Fig 3.

The gun was mounted in a docking station and used a laser sight attached for accuracy in firing. The velocity measure screen was used to determine the velocity of the projectile.

Table 2. Lamination sequence of hybrid samples. 2 by 2 wires(4 wires) (ud or c) 4 by 4 wires(8 wires) (ud or c) 10 layers 14 layers 10 layers 14 layers 3 fiber layers 2 SMA 4 fiber layers 2 SMA 3 fiber layers

4 fiber layers 2 SMA 6 fiber layers 2 SMA 4 fiber layers

2 fiber layers 2 SMA 2 fiber layers 2 SMA 2 fiber layers 2 SMA 2 fiber layers 2 SMA 2 fiber layers

3 fiber layers 2 SMA 3 fiber layers 2 SMA 2 fiber layers 2 SMA 3 fiber layers 2 SMA 3 fiber layers

2.4 Experimental design

To select an appropriate orthogonal array for experimental analysis, the total degrees of freedom need to be computed. The degrees of freedom are defined as the number of comparisons between process parameters that need to be made to determine which level is better and specifically how much better it is. In the present study, the interaction between the

low velocity impact performance parameters is included. In this study, there are 8 of degrees owing to the four

impact parameters and the interactions between parameters. Once the degrees of freedom required are known, the next step is to select an appropriate orthogonal array to fit the specific task. In this study, an L8 (27) orthogonal array was used. Each solid particle erosion wear parameter is assigned to a column where 128 impact parameter combinations are available 11-12).

2m 2m 1m 15 cm

Target plateVelocity measure screen

Test weapon

Witness plate

Fig. 3. Schema of ballistic test setup following the NIJ standard. When energy absorption by plastic deformation under the

impact, plastic deformation was produced a recessed area, by measuring the deflection of the recessed area, span length, in order to calculate a variety of damage energy. The design objective of this study was to maximize the energy absorbed by fibrous laminated composite structures. Total energy absorbed was combined by the energy of delamination, tensile energy and shear bending. Therefore, the objective function can be expressed as the total energy absorbed.

bsTdelt EEEE (1)

Where delE is Delamination energy, TE is tensile energy, bsE is bending and shear energy. The formula for calculating the delamination energy delE is shown below.

Cddel GAE (2)

32

22

819

hEp

Gav

dC (3)

02 hRPd (4)

130 32 S (5)

where dA is the total delamination area, CG is energy release rate, avE is average modulus, dP is first find the delamination load, R is radius of projectile, h is laminate thickness, 0 is average shear stress , 13S is equivalent strength of transverse shear.

The determining the maximum tensile energy in fiber laminated plates. The calculations were as follows:

2

4

1CET (6)

)42(491)(

4518 661222111 AAAAC (7)

where 1C is the laminate material constants, is deflection, is the opposite edge of the back plate laminated two dots of

the span length, ijA is the tensile stiffness) The shear bending energy formula, as shown below.

2bsbs KE (8)


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where

322

6

322

61645252

43

442

FFFFFFFFFFFFFFKbs (9)

55441 49276977754294967296 AAF (10)

6611

2

552 34

5000125.0 DDAF (11)

6622

2

443 34

5000125.0 DDAF (12)

552

74 212773597 AF (13)

442

75 212773597 AF (14)

661226

16 DDF (15)

Where ijA is the tensile stiffness, ijD is the bending stiffness, t is tensile failure strain, is deflection. A total of 8 experimental runs must be conducted, using the

combination of levels for each control factor as indicated in Table 2. Moreover, the results of the experiments are reported in the completed design layout as seen in Table 3. Analysis of the influence of each impact parameter was performed by using MINITAB 16.

Table 3. Experimental layout and results using an L8 (27) orthogonal array. run material

of plate (A)

thickness of plate

(B)

number of SMA (C)

arrangement of SMA (D)

Et S/N ratio (dB)

1 1 1 1 1 618.66 55.65 2 1 1 2 2 636.83 56.26 3 1 2 1 2 702.36 56.36 4 1 2 2 1 455.38 53.74 5 2 1 1 2 194.08 46.33 6 2 1 2 1 163.54 43.70 7 2 2 1 1 629.37 56.16 8 2 2 2 2 704.98 56.78

Table 4. Levels of the variables used in the experiment.

control factor Level I II

A: material of plate Spectra Kevlar B: thickness of plate 10 14 C: number of SMA 4 8 D: arrangement of SMA unidirectional crossover

Design of experiments is a powerful analysis tool for

modeling and analyzing the influence of control factors on performance output. The most important stage in the design of experiment lies in the selection of the control factors. Exhaustive literature review on impact behavior of polymer composites reveals that parameters i.e., impact velocity, impingement angle, fiber loading, material of plate, thickness of plate, number of SMA and arrangement of SMA etc. largely influence the energy absorption of hybrid composites. The impact of four such parameters are studied using L8 (27) orthogonal array. The operating conditions under which impact tests carried out are given in Table 4.

In Table 3, each column represents a test parameter whereas a row stands for a treatment or test condition which is nothing but a combination of parameter levels. In conventional full factorial experiment design, it would require 24 =16 runs to study four parameters each at two levels whereas, Taguchi’s factorial experiment approach reduces it to only 8 runs offering a great advantage in terms of experimental time and cost. The experimental observations are further transformed into signal-to-noise (S/N) ratios. There are several S/N ratios available depending on the type of performance characteristics. The S/N ratio for maximum energy absorption can be expressed as ‘‘upper is better” characteristic, which is calculated as logarithmic transformation of loss function shown as Eq. (16). Larger is the better characteristic:

n

i iynNS

12 )11log(10/ (16)

where ‘n’ the number of observations, and y the observed data. The standard linear graph, as shown in Fig. 4 is used to assign the factors and interactions to various columns of the orthogonal array.

The plan of the experiments is as follows: the first column is assigned to material of plate (A), the second column to thickness of plate (B), the fourth column to number of SMA (C) and the seventh column to arrangement of SMA (D), the third column is assigned to (A×B) to estimate interaction between material of plate (A) and thickness of plate (B), the fifth column is assigned to (A×C) to estimate interaction between the impact velocity (A) and number of SMA (C) and the sixth column is assigned to (B×C) to estimate interaction between the thickness of plate (B) and number of SMA (C), as shown in Table 5 and Fig. 13). 3. Results and Discussion 3.1. Analysis of the results The S/N ratios given in Table 3 are in fact the average of four replications. The overall mean for the S/N ratios of hybrid composites reinforced with SMA are found to be 54.55 db. The analyses are made using the popular software known as MINITAB 16. Before any attempt is made to use this simple model as a predictor for the measure of performance, the possible interactions between the control factors must be considered. Thus factorial design incorporates a simple means of testing for the presence of the interaction effects.

Table 5. Experimental layout an L8 (27) orthogonal array. run 1(A) 2(B) 3(A×B) 4(C) 5(A×C) 6(B×C) 7(D)1 1 1 1 1 1 1 1 2 1 1 1 2 2 2 2 3 1 2 2 1 1 2 2 4 1 2 2 2 2 1 1 5 2 1 2 1 2 1 2 6 2 1 2 2 1 2 1 7 2 2 1 1 2 2 1 8 2 2 1 2 1 1 2

The effects of control factors on energy absorption of

impact for different fiber materials are shown in Fig.5. The analysis of the result gives the combination of factors


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producing maximum energy absorption of the composites. These combinations are found to be different for different fiber composite materials. The factor combination of A2 , B2 , C1 and D1 gives maximum energy absorption. As far as maximization of energy is absorbed concerned, factors A, B and C have significant effects on all hybrid composites whereas factor D has the least effect. It is observed from Fig. 6 that the interaction (A×C) shows most significant effect on energy absorption .

A(1)

B(2) C(4)

D(7)

(3) (5)

(6)

Fig. 4. Linear graph for L8 array.

Fig. 5. Effect of control factors on energy absorption of hybrid composites

Fig. 6. Interaction graph among A, B, C for energy absorption of hybrid composites

The control factors were sorted in relation to the differences in values. The S/N ratios response of the energy absorbed for test specimens is presented in Table 6. This experimental study has shown that the most effective influence on energy absorbed appears due to be variations on the material of plate (A) used for the specimens. That is, the Kevlar into the main structure caused the resulting composite material to exhibit

different resistances against impact; and it was found that, this (Kevlar) has been the most effective parameter among the others. After this parameter, the variation of thickness of plate (B) follows suit. It was found that any changes in these thickness caused significant variations on energy absorbed. The number of SMA (C) and arrangement of SMA (D) come after these first two parameters. Table 6 also shows the variation of S/N ratio of different parameter in level 1 and 2.

Table 6. Response table for S/N ratios. Level A B C D

1 51.8 53.59 55.28 54.7 2 57.29 55.51 53.81 54.4 Delta 5.49 1.92 1.47 0.3 rank 1 2 3 4

3.2. ANOVA and the effects of factors In order to find out statistical significance of various

factors like material of plate (A), thickness of plate (B), number of SMA, (C) arrangement of SMA (D) on the energy absorption of impact, analysis of variance (ANOVA) is performed on experimental data. Table 7 shows the results of the ANOVA with the energy absorption. This analysis is undertaken for 10% confidence level of significance. The last column of the table indicates that all main effects except factor D (arrangement of SMA) but A×C interaction are highly significant since they have very small p-values.

Table 7. Analysis of variance for S/N ratios.

Source DF Seq. SS

Adj. SS

Adj. MS

F P Contribu- tion (%)

A 1 60.34 60.17 60.34 338.25 0.035 62.72% B 1 7.37 7.19 7.37 41.31 0.098 7.50% C 1 4.32 4.14 4.32 24.22 0.128 4.32% D AB 1 3.15 2.97 3.15 17.65 0.149 3.10% AC 1 17.90 17.72 17.90 100.34 0.063 18.47% BC 1 2.67 2.49 2.67 14.95 0.161 2.59% error 1 0.18 1.25 0.18 1.30% Total 7 95.93 95.93 100.00%

The purpose of the ANOVA is to investigate which design

parameters significantly affect the quality characteristic. It was accomplished by separating the total variability of the S/N ratios, which is measured by sum of the squared deviations from the total mean S/N ratio, into contributions by each of the design parameters and the errors. The F value for each design parameters was calculated. Usually, when F > 39.86 it means that the design parameter showed a significant effect on the optimal characteristic.

The last column of Table 7 also indicated the percentage of each factor contribution on the total variation, thus exhibiting the degree of influence on the results. It might be observed in this table that the material of plate (62.72%) had a significant influence on the energy absorption of hybrid composites, while the thickness of plate (7.50%) and the number of SMA (4.32%) follows.


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3.3. Confirmation experiment The final step is to verify the improvement of the quality characteristic using the optimal levels of the design parameters combination and compare with experimental results. Since factor D are not significant, such as A2B2C1 for hybrid composites are considered. The S/N ratios for the composites can be estimated with the help of following prediction equations shown as Eq. (17).

q

imim

1)( (17)

where m is the total mean of the S/N ratio, i is the mean S/N ratio at the optimal level and q is the number of the main design parameters that significantly affect the performance characteristic. According to this prediction, it could be inferred that the S/N ratio was found to be 3.41 dB improvement. This corresponded to about 675.06 m/s, which was the similar value with in the obtained experimental results (Table 8).

Table 8. Results of the confirmation tests.

Initial impact parameters

Optimal impact parameters Experiment Prediction

Level A1B1C1D1 A2B2C1D1 A2B2C1 energy absorption(J)

455.54 676.60 675.06

S/N ratio (dB) 53.17 56.60 56.58 Improvement of S/N ratio =3.41

This table shows a comparison of the predicted energy

absorption with the actual energy absorption using the optimal impact parameters. The increase of the S/N ratio from initial impact parameters to optimal impact parameters was about 3.41 dB, which meant that the energy absorption was increased by about 1.19 times. Therefore, based on the S/N ratio analysis, the optimal impact parameters for the energy absorption for hybrid composites were material of plate (A) at level 1, thickness of plate (B) at level 2, number of SMA (C) at level 1 and arrangement of SMA (D) at level 1.

3.4. Factor settings for maximum energy absorption The relationship between energy absorption with combination of control factors is obtained using linear regression analysis 13-15)model as Eq. (18) with the help of SAS 9.1.3 software for hybrid composites calculated as Eq. (19).

CDDCBAE 543210 (18) ACCBAE 6.408.72.249.797.328 (19)

9688.02r (20) The correctness of the calculated constants is confirmed as

high correlation coefficients (r2) in the tune of 0.95 obtained and therefore, the models are quite suitable to be used for further analysis.

maxmin AAA (21) maxmin BBB (22) maxmin CCC (23)

The suffixes min and max in Eqs. (21)–(23) show the lowest and highest control factors settings used in this study (Table 4).

4. Conclusions

Based on the experimental work, the following conclusions may be drawn for low velocity impact performance conditions used and the characterization of the energy absorption: (1) Such hybrid composites possess fairly good potential for

application in impact environment. Energy absorption characteristics of these composites can be successfully analyzed using Taguchi experimental design scheme.

(2) It was found that the parameter design of the Taguchi method provides a simple, systematic and efficient methodology for the optimization of low velocity impact performance parameters. Taguchi’s robust orthogonal array design method is suitable for analyzing the energy absorption as described in this paper.

(3) The energy absorption performance of hybrid composites improves with the incorporation of particular fillers. Among the two fiber materials chosen for this study, Kevlar was found to be the one causing the maximum enhancement in the impact resistance of the composite under similar test conditions.

(4) The confirmation experiments are conducted to verify the optimal impact parameters. The improvement of energy absorption from the initial impact parameters to the optimal energy absorption parameters is about 119%.

(5) Interaction between material of plate (A) and number of SMA (C) of hybrid composite material leads to an increase in energy absorption. This is due to the structure that the added SMA formed a strong bond with fiber/epoxy laminates and thus rendering the resulting specimens made of this material improved hardness and tensile strengths which account for the increasing energy absorption.

(6) According to ANOVA results, the most significant factor in affecting the energy absorption is the material of plate (A) having a percentage contribution of 62.72% and A×C interaction having a percentage contribution of 18.47%.

(7) Factors such as material of plate (A), thickness of plate (B) and number of SMA (C) are found to be the significant control factors affecting the energy absorption. The arrangement of SMA(D) is identified as the least significant parameter as far as the impact of such composites is concerned.

(8) Optimal factor settings for maximum energy absorption of any composite can be determined using an effective technique based on linear regression. The rationale behind the use of line regression lies in the fact that it has the capability to find the global optimal parameter settings whereas the traditional experimental work is normally stuck up at the local values.

(9) In future, this study can be extended to new hybrid composites using different fiber, ceramics or alloy combinations and the resulting experimental findings can be similarly analyzed.

References

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advanced materials for the 21st Century, Materials & Design, 21(2000), pp.503-505.


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low velocity impact performance analysis of fiber

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