Aircraft Aging and Durability Project

Progressive Damage Analysis of Composites

Carlos G. Dvila Cheryl A. Rose

External Collaborators
Pedro P. Camanho Pere Maim, Albert Turon

Damage Mechanisms in Laminated Composites

E Gamstedt, SE

R Olsson, Imperial College, UK

-45

fiber kinking

ST Pinho, Imperial College, UK

+45

90
P Camanho, U. Porto, PT C Soutis, Sheffield, UK

Finite Element Idealization of Structural Damage

Intralaminar Damage
continuum damage models (CDM)

Delamination/Debonding
fracture mechanics approaches cohesive elements

Through-the-thickness crack
fracture mechanics and modifications strain softening

High Fidelity 3D Models

RVE models (unit cell) transversely isotropic damage model (TIDM)

LaRC04 in Continuum Damage Model (CDM)

Gibbs Free Energy

Strains: Lamina Secant Relation

Rate of Damage Growth

Compression

Tension Softening

fi: LaRC04 failure criteria as activation functions

CDM ensures consistent material degradation and mesh-independent solution

Progressive Damage Analysis

Damage Modes:
Tension Compression

LaRC04 Criteria
In-situ matrix strength prediction Advanced fiber kinking criterion Prediction of angle of fracture (compression) Criteria used as activation functions within framework of damage mechanics Ongoing work: refinements of theory in 3D stress state and more accurate material nonlinearity

Damage Evolution:
Thermodynamically-consistent material degradation takes into account energy release rate and element size for each mode.
"

Bazant CBT: Critical (maximum) finite element size:

Validation of Progressive Damage Analysis

Prediction of size effects in notched composites
Stress-based criteria predict no size effect. (Camanho, 2007) LEFM, Point-Stress Method need empirical calibration. CDM damage model predicts scale effects w/out calibration.

Hexcel IM7/8552 [90/0/45/-45]3s CFRP laminate

Challenges in Progressive Damage Analysis

Splitting Interactions between matrix cracks and delamination

B. Cox, 2007

P. Camanho, 2007

NRA Awards

Crack jumping

E. Iarve, 2007

Quasi-static Cohesive Damage Model

LaRC Decohesion Element Bilinear Traction-Displacement Law

$#
t!0 K
"#

Gc
(1-d)K

! # (" )d" = G
0
"f

"F

Mixed-Mode Fracture

(Technology adopted by ABAQUS, Inc.)

Validation of Mixed-Mode Delamination Model

DCB, ENF and MMB test over PEEK/AS4 composite

Shell Cohesive Elements

Shell cohesive elements allow
simpler, more efficient analysis models

Formulation
Shell kinematics (FSDT) tj 0 +1 0 0 2 ' uk $ + tj ! ! + 0 & v k # = +0 1 0 m 2 !w ! 0 0 % k " 3 D +0 0 1 + + ,
'u $ *! j ! 0( v j ! ! (! ! !w j ! j k 0( & # or U 3 D = R kj U Shell ( . xj ! ! 0( !. ! ( yj ( !. ! ) ! zj ! % " Shell

Shell cohesive element calculation

K Shell. = R T K 3 D R
N , d a o l
350

and

FShell = R T F3 D
Linear Linear
Test [Reeder, 2002]

Example: MMB test

Analysis results
300

Gc=1.12 N/mm
Gc = 1.123 N/mm

Test

Applied load, N.

d e i l p p A

250

3D Analysis Turon 2006

3D Analysis
Shell analysis

200

150

Shell Analysis

100

50

Results indicate good correlation between 3D analysis, shell analysis, and experimental results
0 1 2 3 4 5 6 7 8

Applied displacement, mm. Applied displacement, mm.

Efficient Analyses w/ Shells & Cohesive Elements

Skin-flange interface Delamination
Matrix cracks

Matrix failures
Layers of material integration points

Matrix failures

3D Model
Displacements magnified 8X

Shell Model

Skin-flange interface, decohesion elements

Efficient Analyses w/ Shells & Cohesive Elements

14-layer shell model of lug

Lugs

Failure Mode: Cleavage

Load

Simulation of Fatigue Delamination Growth

Cohesive element: quasi-static + fatigue damage
Quasi-static damage Fatigue characterization (Paris Law) ENF - Fatigue structural simulation

!A =0 !N

& 'G # (A ! = C$ $G ! (N % c "

Cyclic load

Overload

New cohesive law uses Paris Law to account for fatigue damage growth (Turon-Camanho, 2007). Propagation law bounded by threshold and overload fracture. Model accounts for mode mixity GI/GII and load ratio, R. Model uses standard material properties. Cycle Jump strategy used to reduce re-calculations of structural response.

Threshold

Simulation of Fatigue Delamination Growth

Double Cantilever Beam Mixed Mode Propagation

0,01

Numerical Experimental

dA/dN

1E-3

1E-4

1E-5

Asp, Sjogren, Greenhalgh, J. Comp. Tech. Res., 2001.

1E-6

0,2

0,3

0,4

0,5 0,6 0,7 0,80,9 1

GImax/GIc

Simulation of Fatigue Delamination Growth

Fatigue growth of facesheet debond

Material Characterization

Model of sandwich with fatigue cohesive elements

Predicted Life

Pressure

Traction-Displacement Laws for R-curve Effects

Experiments show that toughness Gc is a function of crack length, a.
F

Damage Tolerance analysis of fuselage

Original and modified softening law for R-Curve

Test results: Pinho, 06, Imperial College, UK.

A trilinear traction law for cohesive elements and for continuum damage models can account for the toughening effect of fiber bridging and fiber pullout.
F
Original, Gc=150

Symmetric FE model of CT specimen

F
Load, N

Modified Trilinear

Original Gc=75

Test

Applied displacement, mm.

High Fidelity Analyses: Micromechanical level

Matrix crack 90 Delamination

Transversely Isotropic Damage Model 0 0

90

High Fidelity Analyses: TIDM

Transversely Isotropic Damage Model (Maim, 2007) Damage defined in principal directions

Compliance Matrix Dissipated energy for crack growth is regularized in terms of element size

! Yd&dt =

G Fracture l*

Micromechanical Level: TIDM

90 0 90

High Fidelity Analyses: Process of Matrix Cracking

Transversely Isotropic Damage Model

[0/904/0]

High Fidelity Analyses: TIDM

TIDM analysis is 3D and provides complete picture of crack propagation

High Fidelity Analyses: TIDM

Comparison of measured and predicted Youngs Modulus and Poissons coefficient using TIDM damage model Ex/E0x %xy/%0xy Ex/E0xy %xy/%0xy

Test [02/904]s Analysis [15/904]s

[ 30/904]s

[40/904]s

Test: J. Varna, Composites Science and Tecnology, 2001.

Validated Tools - Target: SAA w/ Industry Partners

Approach:
Collaborative SAA research between NASA and U.S. Rotorcraft Companies through CRI (T.K. OBrien) Develop analytical methodologies to predict composite structure fatigue life and damage tolerance Define/conduct delamination characterization testing needed for analysis input parameters (specimens provided by Sikorsky/Bell)

Validation Test Articles:

Durability
Helicopter main rotor blade spar subjected to tension/torsion fatigue loading

Damage Tolerance
Stiffened tilt-rotor wing skin panel, post BVID, compression fatigue loading, residual strength

Bell Sikorsky

Damage Models: Summary of Progress

Continuum damage model:
! ! " Uses LaRC04 criteria to account for all failure mechanisms. Energetic regularization using element size avoids mesh-dependency. Improved kinematic representation of ply damage needed when damage mode interaction is important. Rigorous kinematic representation of a strong discontinuity. Possesses built-in energetic regularization. Newly developed shell and fatigue cohesive models. Previous information of the possible fracture planes is required. R-Curve toughening can be modeled with trilinear traction-displacement laws. Transversely Isotropic Damage Model can capture all modes of matrix cracking: crack initiation and propagation through the thickness and along the fibers. process of crack saturation. linking of matrix transverse cracks and delamination. Requires several elements through the thickness of every ply.

Cohesive models:
! ! ! " ! !

Traction Curves for R-Curve Effect: High-Fidelity 3D Models:

"