Search

This study looks at the feasibility of using structural optimization techniques to address the problem of designing composite fuselage frames for crashworthiness. A key feature of any optimization strategy for increasing structural crashworthiness is a progressive failure analysis. Currently, the most widely used analysis methods for progressive failure of composite structures are considered too expensive computationally for practical optimization in today's computing environment. Developing an efficient analysis method for progressive failure of composite frames is a first step in the optimization for crashworthiness. In the current work a progressive failure analysis for thin-walled open cross-section curved composite frames is developed using a Vlasov type beam theory. A curved thin-walled composite beam theory is developed and a finite element implementation of the beam theory is used for progressive failure analysis. The accuracy and limitations of this analysis method are discussed. A model for progressive failure of the composite fuselage frame is developed from an extension of the laminate progressive failure analysis of Tsai-Wu. Comparisons based on a limited amount of available experimental data are encouraging. The first major failure event is captured by the theory, and the prediction of total energy absorbed follows the trend of the experimental data. It is believed that this accuracy is sufficient for preliminary design and optimization for crashworthiness. This progressive failure analysis is then incorporated into a frame optimization for crashworthiness based on the genetic algorithm method. The optimization methodology is demonstrated analytically to obtain frame designs with substantially increased crashworthlness. Laminate stacking sequence and cross-section shape are design variables for optimization Ph. D.

Shape memory alloy (SMA) materials such as nitinol have unique properties associated with the shape recovery effect and the material’s phase changes that have been used in a variety of actuator and sensing applications. By embedding SMA elements into host composite materials, control or modification of the SMA hybrid composite’s structural properties can be accomplished in-service, thereby increasing the hybrid composite’s structural functionality. Previous studies addressed increasing composite materials’ functionality by enabling in-service control of their dynamic response. Utilizing the SMA’s substantial recovery stress and capacity to dissipate strain energy to increase the hybrid composite’s static functionality is addressed herein. Specific applications for SMA hybrid composites include improving composite material’s impact damage resistance and composite cylinder stress and deflection control. In stress and deflection control of cylindrical structures, SMA actuators are placed within the composite cylinder to form an active compound cylinder. The active SMA elements can significantly reduce the internal pressure-induced radial dilation and creep so that under severe loading, piston to cylinder tolerances may be maintained. Similar to a conventional metallic compound cylinder, the active compound cylinder also reduces peak cylinder hoop stresses. Hybridizing composites with nitinol improves their impact resistance because of nitinol’s tremendous capacity to absorb impact strain energy through the stress-induced martensitic phase transformation. The amount of impact damage is reduced and the material’s resistance to impact perforation at various velocities is improved. The experimental response of nitinol hybrid composites and the associated mechanics are presented. The unique toughness and resistance to permanent deformation that is a result of the stress-induced martensitic phase transformation enables the nitinol to absorb on the order of 4 times the strain energy of high alloy steel and 16 times that of many graphite/epoxy composites. In most static applications where SMA elements are used for reinforcement, maintaining the integrity of the interface between the SMA elements and the host polymeric matrix composite material is critical to operation. The relationship between preparation of SMA elements for hybrid composite fabrication and interfacial bond strength is presented to address this issue. The mechanics of interfacial shear failure between SMA element and composite is also presented. Ph. D.

Accurate mechanical properties are critical to the design and use of composite material structures. Due to the available processing methods, the properties of ceramic matrix materials are especially sensitive to the geometry of the component and how it is made. A method is presented by which the ply-level elastic properties of a composite material can be obtained for a common structure; a thick, laminated tube. The mechanical and thermal response of the tubes is modeled by a planar cylindrical elasticity solution. Properties are determined from surface strain measurements of a thick tube subject to axial, torsional, pressure, and thermal loads. All elastic properties (including thermal expansion coefficients) can be obtained except the out-of-plane shear moduli (G13, G23) which are not involved in the planar elasticity solution employed. The ply-level properties are estimated by inversion of the elasticity solution in terms of the global strain measurements. A Least Squares optimization approach is used for the inversion of the elasticity solution. Application of the method for a filament wound aluminum oxide-aluminum oxide tube is presented. Advantages and limitations of the method are identified. Master of Science

The influence of layer waviness in thick cross-ply composite cylinders subjected to hydrostatic pressure is investigated. The cylinders considered are graphite-epoxy with a 2: 1 ratio of circumferential to axial layers. All cylinders considered contain 104 total layers with a layup of [90/(90/0/90h71s, where a '0° 1 layer is taken to be in the axial direction. The influence of a single isolated group of wavy layers in an otherwise perfect cylinder is evaluated. Layer waviness in only the circumferential direction is considered, and the analysis is assumed to be valid only away from the cylinder ends. A parametric investigation is performed to determine the combined influence of wave location, wave amplitude, and cylinder geometry on hydrostatic response of the cylinder, particularly the stresses generated in and around the wave. The wave is assumed to be located either at the inner or the outer radius of the cylinder. Three wave amplitudes, 0, are considered: 1/2, 1, and 2 layer thicknesses. Only waves with a half wave length of 10 layer thicknesses are considered. Three cylinder geometries are considered, specifically ones with radius to thickness ratios of 5, 10, and 20. Finite element analysis is used to determine the stress state within the imperfect, i.e., wave included, cylinders. Based on a maximum stress failure criterion, failure pressures are determined for each of the various wave and cylinder geometries. Failure pressures for the imperfect cylinders are compared with those for a perfect cylinder to determine the failure pressure reduction ratios due to fiber waviness. It is shown that pressure capacity reductions of approximately 50% are possible for the range of parameters studied. Failure is primarily due to fiber compression, though interlaminar shear and interlaminar tension are a factor. Finite element analysis is also used to deter ine the failure pressure of the perfect cylinder due to buckling. This is done to determine whether failure due to buckling may overshadow material failure due to fiber waviness. It is shown that buckling is a factor in only one of the cylinder geometries considered, and only in the cases of mild layer waviness. In addition to results, details about the finite element model are presented. These details include geometry of the wave, changes in material properties due to local fiber rotation and local volume fraction changes, boundary conditions, and justifications for modeling simplifications that were made in an effort to reduce computational costs and analysis times. Master of Science

A computationally efficient analysis approach is developed to predict buckling load of geodesically stiffened composite panels under in-plane loads. The analysis procedure accounts for the contribution of the in-plane extensional and out-of-plane bending stiffnesses of the stiffeners through the use of Lagrange multipliers in an energy method solution. The analysis is used to isolate the effect of various stiffener deformation modes on the buckling load and skin deformation patterns of geodesically stiffened panels under various load combinations. The analysis routines are then coupled with the numerical optimizer ADS to create a package for the design of minimum-mass stiffened panels, subject to constraints on buckling of the panel assembly and material strength failure. Material failure in the skin and stiffeners are estimated using a maximum strain criterion. The design variables that can be used for optimization include thickness of the skin laminate, stiffener thickness and height, and positions of straight stiffeners. Applied loads are uniaxial compression, pure shear, and combined compression-shear. Master of Science

Two comprehensive composite fabrication simulation computer codes have been written. These codes when coupled together have the capability to model the filament winding and curing processes for composite structures. The "Filament Winding Cure" (FWCURE) code is a thermo-kinetic model. FWCURE models the resin viscosity, percent of cure, temperature, resin flow, and layer location. As these characteristics change, they have an effect on the fiber tension within the composite. The "Winding and Curing Stress Analysis Finite Element" (WACSAFE) code models the filament winding process and predicts manufacturing stresses and strains based on material properties, lay-down tension and wind angle. The permeability model in FWCURE requires constants that are found experimentally. The WACSAFE code requires an input tension that is equivalent to the initial spool tension minus the instantaneous tension losses. The permeability constants and the instantaneous tension losses were found experimentally. The codes were then used to predict fiber tension, tension losses and mandrel strains for experimental test cylinders. The predictions were compared to test data. Master of Science

Shape memory alloy (SMA) hybrid adaptive composites are a class of materials which combine the strain recovery and elastic properties transformation capabilities of SMA fibers with the structural characteristics of advanced composite materials. This study utilizes the Rayleigh-Ritz method and finite panel acoustic radiation theory to investigate the use of SMA hybrid composite materials for adaptive structural acoustic control by active structural tuning. Analytical models are formulated considering classical laminated plate theory (CLPT) and first-order shear deformation theory (FSDT), to predict modal and structural acoustic response to incident low frequency plane wave acoustic excitation. The analysis is further developed to consider simply supported adaptive panels that are tuned by local fiber activation, such that a panel composed of elastically uniform sections can be evaluated in a piece-wise fashion. Master of Science

Composite materials are considered here as structural materials of highway bridge superstructures. Bridge deck designs can be done according to AASHTO¹ specification and elastic design concepts. In order to evaluate the feasibility of composites as structural materials of highway bridge superstructures, composite materials are compared not only to composite materials themselves but also to the most popular bridge structural materials, which are reinforced concrete and structural steel. The AASHTO¹ HS2O-44 truck load is selected as the standard loading condition of all designs. Loads other than dead load and live load are not considered. Configurations of the bridges are different. Appropriate cross-section of girders are selected according to the material types. For fiber reinforced composite materials, box girder is used, for reinforced concrete, T-beam is selected; in addition, steel concrete composite section is another case. Design methods are different from material to material. Reinforced concrete T-beam design is based on the 'Ultimate Strength Design' method. Steel concrete composite sections are designed according to the 'Load & Resistance Factor Design'. For composite materials, 'Elastic Design' is selected. The results derived are as expected. Substantial weight saving is achieved by simply replacing concrete or steel with composite materials. This also results in many other advantages such as construction time, cost, foundation settlement and support requirements. Master of Science

A Global-Local finite element approach was used to investigate the interlaminar stresses in laminated composite plates with a central circular hole. Detailed solutions were sought for the interlaminar normal stress distributions close to the free straight edge of the plate as well as around the edge of the hole. The Global model was analyzed as a two-dimensional problem. The displacements obtained a distance away from the regions of interest in the two-dimensional model were used as imposed boundary conditions to the three-dimensional models of the edges. The results obtained were found to be accurate, thus demonstrating the validity and strength of the Global-Local technique. The results further concluded that for symmetric cross-ply laminated plates with large central circular holes, the interlaminar normal stresses at the free edges are affected to a small degree by the size of the hole. The CSM Testbed and ANISAP were the two finite element analysis programs used throughout this investigation. The CSM Testbed element library was augmented with 16, 20, 24 and 32 node displacement formulation based elements which were implemented as Experimental elements. Master of Science

In support of crashworthiness studies of composite airframes, the present study was undertaken to understand the large deflection flexural response and failure of graphite-epoxy laminated beams. The beam specimens were subjected to eccentric axial impact loads and to static eccentric axial loads, in order to assess the damage caused by impact. A geometrically and materially nonlinear analysis of the response and failure of the static test specimens is presented. The analysis employed an incremental, noniterative finite element model based on the Kantrovich method and a corotational solution technique. Width-wise effects are included by assuming specific forms of the displacements across the width, with length-wise variation introduced as a degree of freedom. This one-dimensional, 22 degree of freedom finite element accurately predicted the load-deflection and strain-deflection responses of the static test specimens. Inclusion of nonlinear material behavior was found to be important in correctly predicting load-deflection response of uniaxial materials, while inclusion of width-wise effects was determined to be more important for laminates with off-axis plies due to the existence of coupling between bending and twisting curvatures (D16and D26). Once material nonlinearity begins to occur in flexure, even symmetric laminates exhibit bending-stretching coupling due to different material response in tension and compression. Master of Science

The need for better impact resistant composites has resulted in the development of many toughened resin systems. A combination of a tougher resin system along with higher strength fibers increases the impact resistance of the composite. The use of an adhesive layer between two plies of the improved prepreg system has been found to considerably increase the impact resistance. This concept is known as "Interleafing." This investigation studies the response of the interleaf materials to instrumented drop weight impact as compared with the response of non-interleaved materials. Two non-destructive quality evaluation techniques, namely, ultrasonics and eddy currents, are used to qualitatively evaluate the damage developed in the specimens. Several different energy levels of damage are studied. The interleaved laminate had significantly better impact response than the non-interleaved laminate for the same impact energy. The onset of delamination was delayed by the use of the interleaf. Whereas damage could be detected at an impact energy as low as 1.75 ft-lb in the baseline laminate; the interleaved laminate did not show any ultrasonic C-scan indication up to an impact of 2.45 ft-lb. The increase of delamination with increasing impact energy was slower in the interleaved specimen. The eddy current method is not effective in detecting damage in the interleaved laminate because of the shielding effect of the interleaf. Compression Strength After Impact (CSAI) could not be used for the test laminates in this project, but the Tensile Strength After Impact test provided useful results. The tensile strength after impact of the interleaved specimen was between 20%-80% more than the baseline laminate up to impact energy of 10 ft-lb. The advantage of the interleaved specimen reduced at higher energy levels of impact. Master of Science

An investigation of the behavior of shear deformable plate finite elements is conducted to determine why and under what conditions these elements lock, or become overly stiff. For this purpose, a new analytical technique is developed to derive the exact form of the shear constraints which are imposed on an element when its side-tothickness ratio is large. The constraints are expressed in terms of the nodal degrees of freedom, and they are easily interpreted as being either the proper Kirchhoff constraints or spurious locking constraints. Moreover, the technique is applicable to any displacement-based shear deformable beam, plate or shell element regardless of the shear deformation theory or the order of the Gauss-Legendre integration rule which is used to numerically evaluate the stiffness coefficients. To gain a better understanding of locking phenomena, the constraints which arise under full and reduced integration are derived for various Mindlin and Reddy-type beam and plate elements. These analytical findings are then compared with numerical results of isotropic and laminated composite plates, verifying the role that shear constraints play in determining the behavior of thin shear deformable elements. The results of the present study lead to definitive conclusions regarding the origin of locking phenomena and the effect of reduced integration. Master of Science