Institute of Space Technology FORM TH-1

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Request for Approval of Master’s Thesis Topic

Name: M. Fahim Reg No: 150712008

Department: Mechanical Engineering
Specialization: Mechanical Design and Analysis
Start Date: ________
Request approval to prepare and present a thesis in partial fulfillment of the
requirements for the Master’s Degree in Mechanical Engineering
Thesis Title:
Optimization of hole geometry in long fiber reinforced composites using multiscale
modeling against failure
Brief Description/Abstract
Multiscale modeling is a kind of modeling which in which different models at different scales are
used to describe a system, these models focus on different scales of a models, the need of different
scales is produced due to a fact that micro scale models are not so efficient and macro scale models
lag in accuracy. And if we use both views the new result will be very useful.
In long fiber products the fiber of the component may undergo failure condition upon loading and
unloading. The fiber matrix may get damaged and the risen displacement may cause crack initiation.
If more layers are used cohesive zone modeling is performed for more details about failure. Work
pieces formed by using different joining methods will be tested under loads and the crack
development near holes will be studied. The holes in this case will acting as notches and are area
near hole will be studied for stress intensity factor. And later on, by using multiscale modeling we will
find out that how fiber fails in these three cases if the fiber undergoes loading by using stress analysis and
cohesive zone modeling. And we will optimize the joining method as well as hole geometry for a better and
crack prevented hole.as we know in most of the mechanical structures used in space sciences and avionics
deals with holes that’s why the research will be very unique in its kind.
This research includes three different methods to make our samples of composites
I. Riveting
II. Adhesive bonding
III. Thread fastening
Level of Research Already Carried Out on the Proposed Topic
Various multiscale computational techniques in the modern era can be classified into the following
two categories: (a) multiple scale expansion methods, and (b) superposition-based methods. In what
follows we briefly review various research activities in the two areas focusing on their strengths and
limitations. [1]
Continuous fiber reinforced polymer-matrix composites under investigation are quite complex
materials. This complexity can be linked to the following main sources: they contain a
hierarchical/multilength-scale microstructure/architecture; Their mechanical response is often quite
nonlinear and rate-/time-/temperature-/ Pressure-dependent; and they are associated with a
multiplicity of complex Phenomena/processes (e.g., filament twisting/buckling, interfilamentous
friction, and Sliding). A detailed examination of the intrinsic makeup of this class of materials
typically
Reveals the existence of eight well-defined microstructural length scales.

Various length scales and the associated material model assumptions/simplifications used in the
study of polymer-matrix composite materials with high-performance fiber-based structures. [1]
Multiscale simulation strategy to carry out virtual mechanical tests of composite materials and
structures. [3]
A multiscale nonlocal damage theory for brittle composite materials has been developed based on the
triple-scale asymptotic expansions of damage and displacement fields. The Closed form expressions
relating microscopic, mesoscopic and overall strains and damage have been derived. The damage
evolution is stated on the smallest scale of interest and the no locality is taken into account to
alleviate the spurious mesh dependence by introducing the weighted phase average fields over the
micro- and meso-phases. Numerical results revealed the superior performance of the three-scale
method over the two-scale damage model for woven composites. [4]
The interfacial load transfer in carbon nanotube/polymer composites has been analyzed by
combining the atomistic molecular structural mechanics approach and continuum finite element
method. Two kinds of interfacial conditions, that is, perfect interface and van der Waals interface, are
considered. [5]
Fracture of a fiber-reinforced composite by three-point bending of a notched beam was simulated
through a multiscale model based on an embedded cell approach in three dimensions. The beam
representation included two regions: one around the notch tip, where full details of the composite
microstructure (including the matrix, reinforcements and interfaces) were resolved, and another
surrounding this region where the composite was represented by a linear thermoelastic, transversally
isotropic homogeneous solid. [6]
The most common methods applied were reviewed to obtain equivalent properties and then consider
full multiscale modelling. Both linear and nonlinear aspects will be covered. Unsmearing is then
dealt with in some detail because it is often neglected while in many cases it is of fundamental
importance. Later on, usual bounds and other estimates are presented, starting from the Voigt and
Reuss bound then it is illustrated asymptotic homogenization and its numerical implementation.
Then mean field approaches are dealt with, then semi-analytical methods are described And
Recovery methods are presented in the finally. [7]
A multiscale model for composite tensile failure has been presented. The model couples phenomena
across a wide range of length scales, starting from the detailed micromechanical phenomena
associated with fiber damage and ending with predictions of strength and reliability of large
components. With this initial work on quasistatic failure as a basis, the accurate determination of
composite performance for specific material systems under more complex conditions of time- and
cycle-dependent loading appears quite feasible. [8]
In the low-cycle fatigue regime and up to the high-cycle regime gross section failures are observed in
SPR joints. Fatigue crack initiation is found to occur on the faying surface of the upper sheet. v3D
elastic FEA shows that the maximum tensile stress concentration in a loaded SPR is located in the
region exhibiting gross section crack initiation. This finding highlights the importance of the cold-
formed geometric nonlinearities in determining joint mechanical strength. Both the fatigue and static
strength of double-rivet SPR joints are found to be strongly dependent on the orientation
combination of the rivets. The combination for which the rivet heads are closest to the loading ends
is found to exhibit the greatest strength. The fatigue life of the double-rivet SPR joints is found to be
no better than one half of that of a similar single-rivet joint, for the same value of applied stress per
rivet. The severity of fretting damage in SPR joints is observed to increase with sheet thickness. [9]
This stress concentration characterization study of a laminate carbon/epoxy has been carried out. The
precision composites with holes is influenced by the loading direction; there is a high agreement
between those stresses for woven fabric composite with an on-axis (weft direction 0) tensile load.
However, in the off-axis direction (90, 45), the comparison does not show a good agreement. [10]

Gap Analysis
In this research our basic aim is to find an optimized solution for the prevention of fiber from
breakage as result of joining process for two parts to that joint is reliable. For this purpose multi scale
modelling is done in which f[1] [1] [1] [1] [1] [1] [1] [1] [1]iber to matrix interface is modelled to
accurately to model interfacial discontinuities which will further increase the modelling accuracy.
Advantages
Incorporation of holes into fiber reinforced polymers is a widely used assembly process. Such holes
when drilled discretize the fibers thus creating a stress raiser. The fiber holes can be optimized by
laying the fiber around the drilled hole. However large scale modelling fails to address these
differences in cut fiber holes and optimized hole geometries. For this puropose a smaller scale model
is incorporated to the larger model to create a multi scale model able to predict the joint behavior.

Scope of Study
 Research is being done separately on hole geometry, cohesive zone bonding and multiscale
modeling while this research will be a combine result of all these aspects
 Composite material will be joined by using riveting, adhesive bonding and by bolting two
parts in which fibers of parts are not broken due to holes
 Analysis of microstructure
 Determination of Mechanical properties i.e. hardness, fracture toughness under dynamic load

Areas of Application
Composites are the most favorable material used for different engineering application in hard and
rough environment and are mostly used in conditions where involvements of high stresses and light
weight. These are generally used in aerospace application, protective suits, automotive structures and
many more.

Student’s Signature:

________________
 Institute of Space Technology

Thesis Supervisor:
Name: Dr. Owaisur Rehman Shah Signature: ________________

Thesis Co-Supervisor:
Name: Dr. Asif Israr Signature:
[1]________________

Committee Members:

Signature:
1. Name: _______________________ ______________________
Signature:
2. Name: _______________________ ______________________

APPROVAL

_________________
Head of Department Date: ________________________

_________________
Dean/VC Date: ________________________
Institute of Space Technology