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Three-dimensional Stress Analysis in Complex Fiber Architecture
Compositesby Using Independent Mesh Method
Composite Testing and Modeling Identification
Dayton OHOctober 20-23, 2008
David Mollenhauer, Tim BreitzmanAir Force Research Laboratory, WPAFB OH
Endel Iarve, Eric Zhou, & Tom WhitneyUniversity of Dayton Research Institute, Dayton OH
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• Tailorable materials and properties!• High Strength-to-Density• High Stiffness-to-Density• Nonconductive & Conductive• Fatigue/Corrosion Resistance• Creep & Stress Rupture Resistance• Controlled (Low) Thermal Expansion• Dimensional Stability• Formable to Complex Shapes• Lower Life Cycle Costs
Motivation
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Outline
• Overwiev• Morphology
• Processing Simulation Based
• Stress Analysis: Independent Mesh Method (IMM)
• Description• Simple Validation
• Experimental / IMM Comparison on Triaxially Braided Composite
• Moiré Interferometry• Virtual Preform Compaction• Description of Models• Results
• Conclusions
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Approaches:
• Directional f.v.f.
• Idealized Tow Path (shape)
• Process Simulation-Based• Method of Digital Chains
• Image-Based• Image reconstruction
• Goal: • Geometry for mechanics model
Fiber Tow Morphology
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5
Stiffness Homogenization
models
Stress Concentrations,Fracture
Imag
e re
cons
truct
ion
Bas
ed m
orph
olog
y
Certification byanalysis
Morphology representation
Morphology & AnalysisOverview
Ana
lysi
s Fi
delit
yD
irect
iona
l Vol
ume
Frac
tion
Dis
tribu
tion
Idea
lized
(sin
usoi
dal)
Fibe
r Tow
Top
olog
y
Pro
cess
ing
Bas
edFi
ber T
ow T
opol
ogy
Sim
ulat
ion
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6
3D MOSAIC, Bogdanovich et al., 1993Binary Model, B. N. Cox et al., 1994
xFEM, Belytchko, et al., 2003
A-FEM, Q. Young, B.N. Cox ,2008Independent Mesh Method, Iarve, E.V., Mollenhauer, D.H., Zhou, E., and
Whitney, T.J.,, 2007Mesh Superposition Methods, Fish, J, et al., 1999
Nakai, H., Kurashiki, T., and Zako, M.,, 2007Domain Superposition Methods, Jiang,W.-G., Hallett, S.R., 2007
Computational Methods
Direct FE discretization Voxel Methods
Overview
Combined methods
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Outline
• Overwiev• Morphology
• Processing Simulation Based
• Stress Analysis: Independent Mesh Method (IMM)
• Description• Simple Validation
• Experimental / IMM Comparison on Triaxially Braided Composite
• Moiré Interferometry• Virtual Preform Compaction• Description of Models• Results
• Conclusions
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Fiber Tow Morphology(simulated via “digital chains”)
• A tow consists of many “digital chains” • Chains
interact through contact elements
virtual compaction
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Fiber Tow Model
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10
Independent Mesh Method
1. Parametric geometryrepresentation for
each yarn
2. Independent meshmodeling of matrix
0 1
1
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Figure 3: Schematic of matrix displacement approximation function definitions, boundary interval integration, and extra degree of freedom elimination.
1. Yarn deformation modeled directly2. Yarn-matrix connection modeled by penalty minimization3. Matrix domain meshed independently
• Shape functions truncated• Volume integration cubes
Independent Mesh Method, Matrix Model
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IMM FEM
Independent Mesh Method, Oval Fiber RVE
IM7- fiber, epoxy matrix
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IMM FEMGRP fiber tow,Epoxy matrix
Independent Mesh Method,Textile RVE
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Outline
• Overwiev• Morphology
• Processing Simulation Based
• Stress Analysis: Independent Mesh Method (IMM)
• Description• Simple Validation
• Experimental / IMM Comparison on Triaxially Braided Composite
• Moiré Interferometry• Virtual Preform Compaction• Description of Models• Results
• Conclusions
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Residual Stress Evaluation
Triaxial Braided CompositeAS4/3501-6
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Residual Stress Evaluation
Triaxial Braided CompositeAS4/3501-6
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• Experiment: 5-layer Compacted triax-braid• Model 1: 1-layer Uncompacted triax-braid (i.e. resin rich)• Model 2a: 5-layer Compacted braid (only top layer modeled)• Model 2b: same as 2b except Virtually “Sanded”
Photomechanics Lab Moiré Interferometry
Experimental Validation(general description of test & models)
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Comparison of Cross-Sections
CT Image of TopPortion ofSpecimen
CompactedMorphology
UncompactedMorphology
(a)
(d)
Compacted,Sanded
Morphology
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Residual Stress Evaluation
Triaxial BraidedCompositeAS4/3501-6
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Data plotted along a line 0.25 mm from the top edge of slot for…
εzz εxx
Extracted Strain Results
Data Line
zx
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Data plotted along a line 0.25 mm from the top edge of slot for…
εzz εxx
Extracted Strain Results
Data Line
zx
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Data plotted along a line 0.25 mm from the top edge of slot for…
εzz εxx
Extracted Strain Results
Data Line
zx
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Data plotted along a line 0.25 mm from the top edge of slot for…
εzz εxx
Extracted Strain Results
Data Line
zx
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Conclusions/Future
• Research Conclusions• Textile morphology tool is on the right track• Independent Mesh Method allows modeling of
otherwise intractable problems• Experimental investigation
• critical step in understanding complex materials• validating new modeling methods
• Future Efforts• Introduce damage with Mesh Independent Cracking• Extract fully-3D textile morphology with CT scan• Add “structural-level” feature/stress concentration
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Uniaxial loading of 3-axial braid(3D X-ray tomography)
Cracks:MatrixInter towIntra tow
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Image segmentation involves noise removal,
histogram, edge detection, line
segmentation, region segmentation, and edge
smoothing
Image reconstruction involves characteristic function
computation, integration, & surface extraction.
optical microscopy x-ray tomography
Fiber Tow Morphology(image-based)