碳纤维增强环氧树脂复合材料层合板干涉连接插钉轴向力建模与分析

碳纤维增强环氧树脂复合材料（CFRP）构件干涉配合连接的插钉轴向力过大会引起层合板弯曲和分层,严重影响产品的安全性。针对CFRP层合板的高锁螺栓干涉连接过程,分析了其制孔、插钉及拧紧等装配连接工艺,将其干涉插钉过程划分为4个阶段,并对各个阶段进行了详细的力学行为分析;对螺栓杆处和倒角处的挤压力和摩擦力分别进行力学建模,并结合各作用力的边界条件与阶段划分,构建了干涉插钉全过程的轴向力模型;通过ABAQUS有限元模拟了CFRP层合板干涉插钉工艺过程,并开展了干涉螺栓安装实验,对比分析了层合板孔周径向挤压应力分布和插钉轴向力变化规律,解析结果与模拟和实验结果吻合较好,为后续CFRP层合板的插钉分层损伤和工艺优化研究奠定基础。      

T300/QY8911 π/4层压板机械连接干涉疲劳

本文对T300/QY8911π/4层压板机械连接干涉配合进行了静拉伸挤压和拉-拉疲劳试验。与滑配合比较,干涉使静挤压强度略有提高,但能使疲劳寿命增加数倍。文中用有限元方法计算了两种配合的孔边应力分布。并对疲劳损伤用X射线作了检测,初步分析了干涉配合的增寿原因。      

Analytical prediction of damage due to large mass impact on thin ply composites

This article presents analytical models for predicting large mass impact response and damage in thin-ply composite laminates. Existing models for large mass impact (quasi-static) response are presented and extended to account for damage phenomena observed in thin-ply composites. The most important addition is a set of criteria for initiation and growth of bending induced compressive fibre failure, which has been observed to be extensive in thin ply laminates, while it is rarely observed in conventional laminates. The model predictions are compared to results from previous tests on CFRP laminates with a plain weave made from thin spread tow bands. The experiments seem to confirm the model predictions, but also highlight the need to include the effects of widespread bending induced fibre failure into the structural model.     

分析复合材料螺栓连接接头静强度的一种方法

根据复合材料机械连接区逐点逐层破坏的物理本质,采用了每层破坏单元刚度退化和应力空间二阶张量破坏准则,用有限元素法,计算了T300/648碳纤维复合材料21种不同铺层情况的接头强度,分析了它们的破坏模式和破坏过程并与试验结果进行了比较.      

一种改进的内聚力损伤模型在复合材料层合板低速冲击损伤模拟中的应用

针对传统内聚力损伤模型(CZM)无法考虑层内裂纹对界面分层影响的缺点,提出了一种改进的适用于复合材料层合板低速冲击损伤模拟的CZM。通过对界面单元内聚力本构模型中的损伤起始准则进行修正,考虑了界面层相邻铺层内基体、纤维的损伤状态及应力分布对层间强度和分层扩展的影响。基于ABAQUS用户子程序VUMAT,结合本文模型及层合板失效判据,建立了模拟复合材料层合板在低速冲击作用下的渐进损伤过程的有限元模型,计算了不同铺层角度和材料属性的层合板在低速冲击作用下的损伤状态。通过数值模拟与试验结果的对比,验证了本文方法的精度及合理性。     

A simplified approach to the damage tolerance design of asymmetric tapered laminates. Part I: Methodology development

Tapered composite laminates are susceptible to interlaminar damage in the form of delaminations growing from ply drop-off locations. This study presents an analytical method for the calculation of the energy release rates associated with interlaminar cracks emanating from the ply termination in both the laminate thick and thin sections, also accounting for the effects of the tapering angle. The proposed approach is based on modeling asymmetrically tapered composite laminates as assemblies of layered Euler–Bernoulli beam segments; these are split and reconnected through-the-thickness at the ply-drop-off location. The presence of a local resin pocket is explicitly considered in the model. Orthotropic rescaling is employed in order to take into account the material behavior through-the-thickness. This paper presents the analytical formulation of the proposed approach, whose validation follows in part II.     

碳纤维复合材料层合板低速冲击损伤应力分析

目的 为掌握碳纤维复合材料板在低速冲击载荷作用下的损伤规律,延缓失效破坏,对其冲击损伤的应力状态进行研究。方法 基于ABAQUS平台,建立碳纤维复合材料层合板低速冲击有限元模型,采用Hashin失效准则和VUMAT用户子程序,对碳纤维复合材料层合板的冲击过程进行数值模拟,同时考虑层合板层内与层间失效,以此来研究低速冲击条件下复合材料的损伤机理,分析冲击损伤过程中的应力变化趋势,讨论应力的分布状态。重点研究铺层角度及铺层距离冲头远近对应力的影响。结果 不同角度铺层的应力传播轨迹均沿着纤维方向和垂直于纤维方向同时扩展,应力均先增加至极限值而后迅速下降;铺层角度越大,板料的承载能力越弱,0°铺层的极限应力为1 432 MPa,而90°铺层的极限应力降至1 206 MPa;离冲头越远的铺层应力越小,达到峰值的时间更早且率先下降,说明远离冲头的铺层更早发生失效。结论 揭示了碳纤维层合板在低速冲击载荷作用下的应力状态及其对损伤的影响规律,能够为复合材料层合板零件设计提供参考。     

Prediction for delamination initiation around holes in symmetric laminates

The purpose of this paper is to present an analytical technique for predicting the delamination initiation load and delamination location for balanced symmetric laminates containing a hole. Basically, this approach includes two phases. First, the stress distribution around the hole region is calculated by the authors' recently developed efficient method. Second, the delamination initiation load and delamination location are predicted by using an average stress failure hypothesis together with the Hashin-Rotem delamination criterion. A computer program was developed to calculate the delamination initiation load and location for notched laminates with different ply orientations, different material properties and different stacking sequences. Numerical results for (θ/ – θ/0°)_s and (0°/90°)_s composite laminates generated by the current approach are compared with existing solutions. The results show that the present method is very efficient and useful for the purpose of engineering design.     

Ply-interleaving technique for joining hybrid carbon/glass fibre composite materials

Efficiently joining materials with dissimilar mechanical and thermal properties is fundamental to the development of strong and lightweight load-bearing hybrid structures particularly for aerospace applications. This paper presents a ply-interleaving technique for joining dissimilar composite materials. The load-carrying capacity of such a joint depends strongly on several design parameters such as the distance between ply terminations, the spatial distribution of ply terminations, and the stiffness and coefficients of thermal expansion of the composites. The effects of these factors on the strength of quasi-isotropic hybrid carbon/glass fibre composite are investigated using combined experimental, analytical and computational methods. Through fractographic analyses significant insights are gained into the failure mechanism of the hybrid joints, which are then used to aid the development of predictive models using analytical and high fidelity computational methods. To characterise the interaction between transverse matrix cracking and delamination, continuum damage mechanics model and cohesive zone model are employed. The predictions are found to correlate well with experimental data. These modelling tools pave the way for optimising hybrid joint concepts, which will enable the structural integration of dielectric windows required for multifunctional load-bearing antenna aircraft structures.     

Multiaxial fatigue life prediction of composite bolted joint under constant amplitude cycle loading

In this paper, a fatigue model of composite is established to predict multiaxial fatigue life of composite bolted joint under constant amplitude cycle loading. Firstly, finite element model is adopted to investigate stress state of composite bolted joint under constant amplitude cycle loading. Secondly, Tsai–Hill criterion is used to calculate equivalent stress of joint. At last, modified S–N fatigue life curve fitted by unidirectional laminate S–N curve which takes ply angle and stress ratio into consideration is adopted to determine fatigue life of composite. Calculation results of equivalent stress model show excellent agreement with experiments of composite bolted joint.     

准各向同性纤维增强复合材料层合板的开孔拉伸破坏模拟

建立了一种新的有限元三维模型,对准各向同性纤维增强复合材料层合板[45/0/-45/90]_s和[45/-45/90/0]_s进行了开孔拉伸的破坏模拟。每一层均采用三维实体单元(ABAQUS中的C3D8R单元),由于基体比纤维强度低,在很低的拉伸载荷下,圆孔周围基体受到剪切力会出现沿纤维方向的纵向劈裂或基体开裂,从而钝化圆孔,大大减小应力集中,提高材料承载能力。为了准确模拟层合板的破坏,在每层圆孔周围(90°层除外)沿纤维方向引入2组基于表面的内聚力接触来模拟层内纵向劈裂,同时用这种接触来模拟层间的分层特性。为了提高计算效率并且保证计算精度,在圆孔周围采用精细的网格,其余地方采用相对稀疏的网格。在内聚区保证足够的单元个数,这样既能准确刻画内聚区应力分布,又能缓解网格依赖性。与文献中实验结果的对照显示,取得了较好的一致性。      

Moment Distribution around Circular/Elliptical/Triangular Cutouts in Infinite Symmetric Laminated Plate

In this article, a general solution for moment distribution around a circular/elliptical/triangular shaped hole in a laminated composite plate subjected to a bending/twisting moment at infinity is presented. The numerical results are obtained for graphite/epoxy, glass/epoxy, boron/epoxy, etc. The effect of loading factor, stacking sequence, material parameters, and hole geometry on moment distribution is studied for cross ply and angle ply laminates. The results are compared with existing literature and found to be in good agreement.     

Predicting evolution of ply cracks in composite laminates subjected to biaxial loading

An energy-based model is developed to predict the evolution of sub-critical matrix crack density in symmetric multidirectional composite laminates for the case of multiaxial loading. A finite element-based numerical scheme is also developed to evaluate the critical strain energy release rate, G_Ic, associated with matrix micro-cracking, a parameter that previously required fitting with experimental data. Furthermore, the prediction scheme is improved to account for the statistical variation of G_Ic within the material volume by using a two-parameter Weibull distribution. The variation of G_Ic with increasing crack density is also accounted for based on reported experimental evidence. The simulated results for carbon/epoxy and glass/epoxy cross-ply laminates demonstrate the ability of the improved model to predict the evolution of multidirectional ply cracking. By integrating this damage evolution model with the synergistic damage mechanics approach for stiffness degradation, the stress-strain response of the studied laminates is predicted. Finally, biaxial stress envelopes for ply crack initiation and pre-determined stiffness degradation levels are predicted to serve as representative examples of stiffness-based design and failure criterion.     

螺栓连接层合板孔边挤压应力三维分布

孔边应力是复合材料连接设计中强度校核的重要依据,装配间隙对其有明显的影响。针对准各向同性铺层层合板单搭接连接结构,首先采用弹性基剪切梁模型推导了螺杆挠度的解析解,给出挤压载荷沿着层合板厚度方向的分布。在此基础上,将能计及装配间隙的二维情况下孔边挤压应力分布的Persson模型推广到三维情况,得到了孔边挤压应力分布及应力集中系数。理论结果通过三维细节有限元方法进行了验证。最后采用理论方法分析了装配间隙、层合板厚度及钉载对应力集中系数的影响。     

Optimisation of the protrusion geometry in Comeld™ joints

Design solutions using composite laminates frequently require joining the laminates to metal. A novel approach to such bonding using a sculpted metal surface has been proposed which can be described as a combination of mechanical and adhesive bonding. Optimisation of the protrusion geometry on the sculpted metal surface has been studied numerically with the finite element method using a simplified model for the end protrusion where initial failure is observed. The angle and height of the protrusion are found to significantly affect the stress concentrations around the protrusion which initiate failure. It is predicted that the optimum angle is opposing the shear and that higher protrusions are more likely to prevent joint failure.     

Application of the point stress criterion to the failure of composite pinned joints

An analysis was performed to evaluate the bearing strength of pin-loaded composite joints using a two parameter characteristic curve model. This model involves determination of characteristic dimensions in tension and compression and based on this model, a two-dimensional stress analysis was used to determine the stress distribution around the fastener hole. In this analysis, characteristic dimensions in tension and compression were evaluated using the point stress failure criterion and joint bearing failure evaluated using the Yamada-Sun failure criterion. Results were compared with available experimental data for joints made from AS4/3501-6 graphite epoxy composite laminates and good correlation observed when evaluated as function of edge distance to hole diameter. However, the analysis yields conservative results when joint strength is evaluated as a function of plate width to hole diameter.     

Matrix crack-induced delamination in composite laminates under transverse loading

Fibre-reinforced multidirectional composite laminates are observed in experiments under transverse static or low-velocity impact loading to suffer considerable delamination damage. The intensity of this damage depends on the difference in the ply angles above and below the interface. In this paper a fracture mechanics model is presented for investigating the role of matrix cracks in triggering delaminations and the influence of ply angles in adjacent plies on delamination cracking. The fracture mechanics analysis shows that for a graphite fibre-reinforced composite laminate containing a transverse intraply crack, the crack-induced largest interfacial principal tensile stress is a maximum when the difference between the ply angles across the interface is 90 °, and it attains a minimum when the difference is 40 °. When the crack tips touch the interfaces, the minimum mode II stress singularity, which is weaker than the usual square-root type, appears when the difference between the ply angles is about 45 ° for one glass fibre-reinforced laminate and three graphite fibre-reinforced laminates. These results are in agreement with the experimental observation that the largest delaminations appear at the interface across which the difference between the ply angles is the largest i.e. 90 °.     

Interlaminar Stress Determination in Carbon Fibre Epoxy Composites with the Embedded Strain Gauge Technique

Abstract: In order to determine interlaminar stresses, strain gauges have been embedded in carbon fibre/epoxy composites. Insulation problems occurring because of the electrical conductivity of the carbon fibres were successfully resolved with the help of special foils. Measurements on unidirectional and angle‐ply laminates were in good agreement with calculations based on the classical laminate theory. Moreover, the laminate strength was not significantly affected by the embedded strain gauges. The technique may also be applied to residual stress determination in composite components.     

铺陈角度对芳纶/玻璃纤维层合板抗冲击性能的影响

采用Abaqus软件建立了圆锥形子弹正冲击芳纶/玻璃纤维复合材料层合板的有限元模型,将模拟结果与文献中的实验结果相比较验证了模型的可靠性,进而研究子弹以不同的速度对不同铺陈角度下的复合材料层合板冲击后初始速度与剩余速度的关系以及层合板的破坏特征。结果表明:当层合板铺陈角度不变且子弹击穿层合板时,子弹初始速度与剩余速度接近于线性关系;在子弹未穿透层合板时,[0/90°]铺陈角度的层合板抗弹性能最好,在子弹以600~900 m/s的较高速度穿透层合板时,[45/-45°]铺陈角度的层合板吸能效果最好;由破坏特征图表明铺陈角度对层合板的损伤面积和破坏机制影响不大。该研究可为防护装备的设计和优化提供参考。     

Experimental study on clamping effects on the tensile strength of composite plates with a bolt-filled hole

An experimental study was performed to assess the effects of clamp-up on the net-tension failure of laminated composite plates with bolt-filled holes. Graphite/epoxy prepreg of T800/3900-2 was selected for fabricating the laminates for the tests. The tensile strength and failure response of specimens with an open hole and a bolt-filled hole were evaluated. Both 100% bypass load (no bolt bearing load) and no bypass load (100% bolt bearing load) were considered during the experiments. X-radiographs were taken for specimens after pre-loading at different stress levels for the purpose of characterizing the failure modes and damage progression inside the composite.Experimental results showed that the bolt clamping force can significantly reduce the notch tensile strength of composite laminates which are prone to fiber-matrix splitting and delamination. A reduction in failure load of up to 20% was observed. Higher clamping pressure resulted in higher reductions of notch strength. However, for bolted joints which failed in a net-tension mode, clamping improved the joint strength regardless of the ply orientation.