Fatigue failure transition analysis in load‐carrying cruciform welded joints based on strain energy density approach

This paper details a study of the application of notch stress intensity theory to the fatigue failure mode analysis of the transition in load‐carrying cruciform welded joints. The weldment fatigue crack initiation point is difficult to predict precisely because it usually occurs in the vicinity of the weld toe or weld root. To investigate the relationship between fatigue failure location and the geometry of the weldments, we analysed the weld toe and root asymptotic notch stress fields were analysed using the notch stress intensity factors on the basis of the Williams' solution in Linear Elastic Fracture Mechanics (LEFM). Numerous configurations of cruciform joints of various plate thicknesses, transverse plate thickness, weld sizes and incomplete penetration size were used to investigate the location of the fatigue failure. The strain energy density (SED) surrounding the notch tip was introduced to unify the scalar quantity and preclude the inconsistency of the dimensionality of the notch stress intensity factors for various notch opening angles. The results of the investigation showed that the SED approach can be used to determine the transition zone for a variety of joint geometries. The validity of the SED criteria was verified by comparing the experimental results of this study with the complied results for load‐carrying cruciform welded joints reported in literature.     

A mechanically fastened composite laminate joint and progressive failure analysis

A comprehensive procedure for a mechanically fastened composite laminate joint (ASTM D5961 Proc. A, B) is demonstrated from fixture design to analysis of test results. The ASTM tests are applied to evaluate the standard laminate properties and the composite joints. Composite laminate mechanical joints were analyzed using the finite element method (FEM), and the results were compared to test results. A progressive failure analysis (PFA) was applied to the FEM to predict the overall failure behavior of the test specimens. Three laminate failure theories – maximum stress, maximum strain, and Tsai–Wu – were applied to the PFA to predict the test failure load, displacement and strength. The PFA method was suitable to predict the initial test range of test and maximum test load except for the excessive failure area.     

Limit load analysis of strength undermatched welded T-joints under bending

An increasing amount of laser beam welded T‐joints (e.g. skin‐stringer) of aluminium alloys are now in use in advanced fuselage applications designed as ‘integral structures’ for weight and cost savings. It is known that weld joints generally show lower strength (undermatching) than base metal in both laser beam and friction stir welded joints of 6xxx series Al‐alloys. Damage tolerance considerations in terms of the residual strength of such joints require limit load solutions to be used in engineering fitness‐for‐service (FFS) analysis. The paper, therefore, provides an upper bound limit load solution in closed form for welded T‐joints (idealized) with strength undermatching and subject to a bending moment. In addition to the necessary requirements of the upper bound theorem, the kinematically admissible velocity field chosen leads to a stress field, which satisfies the equilibrium equations and some stress boundary conditions in the plastic zone. This is an advantage of the solution and, therefore, it is expected that the upper bound obtained is close to the exact limit load of such joints.     

Application of interface finite elements to three-dimensional progressive failure analysis of adhesive joints

ABSTRACT The paper presents a new model for three‐dimensional progressive failure analysis of adhesive joints. The method uses interface elements and includes a damage model to simulate progressive debonding. The interface finite elements are placed between the adherents and the adhesive. The damage model is based on the indirect use of fracture mechanics and allows the simulation of the initiation and growth of damage at the interfaces without considering the presence of initial flaws. The application of the model to single lap joints is presented. Experimental tests were performed in aluminium/epoxy adhesive joints. Linear elastic and elastoplastic analyses were performed and the predicted failure load for the elastoplastic case agrees with experimental results.     

The investigation of effect of adherend thickness on scarf lap joints

In this paper, the mechanical behavior of the Scarf Lap Joints (SLJs) bonded with adhesive under a tensile load was analyzed. The effects of adherend thickness at the interface stress‐strain distributions of SLJs were examined. The stress‐strain analyses were performed by Finite Element Method (3D‐FEM). The 3D‐FEM code was employed with Ansys (Ver.12.0.1). Experimental results were compared with the 3D‐FEM results and were found quite reasonable. It was concluded that both experimental and 3D‐FEM failure loads were increased with increased adherend thickness. The results indicated that the maximum failure loads were determined at t=8 mm in all joints. The analysis of the SLJs under tensile load showed that the stress and strain concentrations occurred around the edges of the joints.     

CFRP复合材料螺栓连接失效载荷不确定性的评估方法

螺栓连接是先进复合材料结构的薄弱环节。因此,螺栓连接力学性能显著的不确定性不仅阻碍了先进复合材料的高效应用,且给整体结构的安全性和可靠性带来威胁。为定量评估碳纤维增强树脂(CFRP)复合材料螺栓连接失效载荷的不确定性,将数值的渐进损伤模型和区间分析方法结合,提出了一种高效、准确的分析方法。采用该方法预测了典型T800碳纤维/X850环氧树脂复合材料螺栓连接失效载荷的不确定性,并与试验结果进行对比。预测结果与试验结果的误差不超过2%,证明本文所提出方法的有效性。采用本文所提方法预测的T800碳纤维/X850环氧树脂复合材料螺栓连接失效载荷的区间为[19.25 kN, 22.75 kN],与设计期望值的偏差为[?9.8%, 6.6%]。      

Procedure to predict ultimate fracture failure history for plane stress plasticity problems

A finite element solution procedure is presented to predict the load-displacement history up to ultimate fracture failure for a structural system. Incremental plasticity theory for the von Mises yield criterion and isotropic strain hardening are used to march along the uniaxial stress-strain curve of the material up to fracture. When an element fractures its strain energy is distributed into the unfractured elements using an element nodal release method. If another element fractures during this redistribution process, then unstable crack growth is said to occur, and the total load at this stage is termed the ultimate fracture failure load of the structural system. The analysis steps to automate the solution procedure are described. Numerical results obtained for a center pre-cracked panel tension specimen are reported and compared with experimental results available in the literature.     

Numerical and experimental failure analysis of screwed single shear joints in wood plastic composite

In this research, effects of end distances and thicknesses of side and main members on failure loads and also modes of failure of single shear plane joint, made on wood plastic composite (WPC) were studied, both experimentally and numerically as well. Yamada-Sun failure criterion was used to determine failure loads of this kind of joints fabricated on WPC and results were compared with that of experimental observations. Numerical analysis was made by making use of ABAQUS finite element (FE) software. Experiments were conducted according to ASTM D-1037. Predicted failure loads by numerical models were in good agreement with those observed experimentally. Results have indicated that failure load of tested joint is dependent on end distance and thickness of corresponding members as well. Failure modes were determined both by numerical models and tested joints. FE models were used to perform stress analysis.     

A unified fatigue failure criterion for unidirectional laminates

A unified fatigue failure criterion using micromechanics related to the fracture plane has been developed to predict fatigue lives of unidirectional fibre reinforced polymer composites subjected to cyclic off-axis tension–tension loading. Since the failure criterion incorporates both stresses and strains it may be characterized as energy based. Accounting for the fibre load angle as well as the stress ratio is the novelty of this fatigue failure criterion. The criterion only requires the stress ratio to be known from the experimental procedure. The relation between the applied load and the micro-stress and micro-strain field can be determined from a numerical method. The fatigue failure criterion has been verified by applying it to different sets of experimental data. Several fibre load angles, different fibre/matrix combinations as well as stress ratios are covered. The predicted fatigue lives are in good agreement with the experimental results for both different fibre load angles and stress ratios.     

On the Bearing Failure of Laminated Composite Pin‐Loaded Joints: Exploitation of Semi‐Analytical Solutions for the Determination of the Stress State

Abstract: The present work deals with the development and verification of a set of analytical solutions for the bearing failure of single lap composite joints, which are applied on a composite joint tested experimentally. The stress field originating from the solution is calculated and progressive failure criteria are applied, verifying their applicability as a fast way of calculating bearing failure of a joint. Additionally, the extracted stress field from the results is introduced as a load to the finite element model of the joint under evaluation, and the equivalency of this method is compared and proven against typical implicit non‐linear contact analysis. The major advantage of the proposed methodology is that the highly non‐linear contact problem is circumvented using the stress distribution at the hole boundary as an actual load and thus transforming the analysis to a linear one, providing considerable agreement to the exact high‐cost numerical solution.     

Rib loading effects on weld root fatigue failure modes at rib‐to‐deck welded joint

The service life of orthotropic steel decks is dependent on the fatigue resistance of rib‐to‐deck welded joints, which is often tested using two kinds of experimental models in terms of the rib loading condition. Different weld root fatigue failure modes have been observed in the different models, but the role of rib loading remains unclear. This paper aims to clarify the effect of rib loadings on the weld root fatigue failure modes at rib‐to‐deck welded joints. The loadings are decomposed into the deck loadings and rib loadings according to the principle of superposition. Formulae of the weld root notch stress intensity factors and T‐stress under rib loadings are developed by multiparameter regression analysis and subsequently used for the local stress analysis. The fatigue failure modes determined from the local stress field agree well with the experimental results. The results reveal that the weld root failure modes depend on the rib loadings but are independent of the weld geometries. The averaged strain energy density (SED) that can capture both weld geometry and loading condition effects is used to correlate the fatigue test data of different weld root failure modes. The SED is capable of evaluating the fatigue strength of the rib‐to‐deck welded joint failed by different weld root failure modes with a narrow scatter band.     

An experimental investigation on the adhesive,shear strength,and failure modes of glass fibre reinforced polymer flat-joggle-flat composite joints over different bonding techniques

The utilisation of composite materials, especially glass fibre-reinforced polymer has significantly developed as a result of design innovations in aircraft applications. Joints are a major issue as they are the weak point of composite construction. In this study, considering a flat-joggle-flat joint over the single-lap-joint, the effect of different manufacturing techniques on co-bonding, secondary-bonding, and co-curing for flat-joggle-flat joints on the shear behaviour and dynamic characteristics were investigated. The results affirmed that flat-joggle-flat joints increased the load-carrying capacity by 110 % compared to single-lap joint. In continuance, results revealed that co-cure flat-joggle-flat joints enhanced the load by 86.43 % and 20.00 %, along with increased shear strength of 8.9 MPa over co-bonding and secondary-bonding. Field emission scanning electron microscopy reveals that destructive failure occurs at joints in co-bonding and secondary-bonding due to an increase in stress between the adhesive and the adherend, which can lead to fibre failure and matrix damage. The dynamic characteristics, like fundamental natural frequency, are increased in co-cure flat-joggle-flat joint compared to co-bonding and secondary-bonding joints. The investigation reveals that innovative flat-joggle-flat joints and suitable manufacturing processes improve the shear strength, and dynamic properties of composite joints.     

Failure analysis of woven kevlar fiber reinforced epoxy composites pinned joints

An investigation was performed to determine the failure mode and the failure load of mechanically fastened joints in woven kevlar epoxy composite plates. Two-dimensional finite element code is developed to predict damage initiation, progression and strength of joints. Hashin, Hoffman and Maximum Stress criteria were used in this failure analysis. Experiments were performed to find the failure load and to predict the failure mode. Parametric studies were also carried out to evaluate the effect of joint geometry on this analysis. The obtained results were compared each other and comparison showed good agreement between numerical and experimental methods.     

On phenomenological failure criteria for composite bolted joint analysis

There has been a recent trend to use phenomenological strength models in combination with point stress or average stress failure criteria to form strength models for the analysis of composite bolted joints. Several papers published using these approaches have demonstrated practical reductions in the size of the empirical data base required to perform bolted joint analysis for specific materials and laminates. Since the inception of phenomenological failure models for bolted joints several refinements have been proposed, but the generality of the method is not clearly defined. This paper addresses the concepts underlying the formulation of these strength models, compares the capabilities of several commonly used failure criteria and discusses the limits of applicability through example analyses and comparison with experimental data. The results indicate that differences in predicted strengths for the models examined were insignificant. Failure mode predictions based on single point failure location information varied from model to model and differed significantly from experimentally observed failure modes for some geometries. The models cannot be applied with confidence for the analysis of a wide class of laminates and geometries without calibrating the model through empirical data.     

On the estimation of fatigue failure under fretting conditions using notch methodologies

ABSTRACT According to experimental evidence, the early stages of fatigue crack propagation under fretting conditions are strongly influenced by the stress gradient generated in the material near the contact zone. This suggests that the crack growth process can be analysed using methodologies similar to those employed to predict the fatigue behaviour of notched elements. This paper assesses the applicability of a number of models originally developed for notched components to fretting fatigue problems. The ability of such models to predict fatigue failure is discussed and compared with experimental results for Al 7075‐T6 specimens that were subjected to fretting fatigue under spherical contact.     

The Prediction of Fatigue Crack Initiation Life in Spot Welds

Abstract: In this paper, strain‐based fatigue life prediction method has been used to estimate the fatigue crack initiation life of spot‐welded joints of Mild Steel JSC270D and Ultra‐High Strength Steel JSC980Y. To do so, the joints were simulated using three‐dimensional finite‐element (FE) models, and then nonlinear FE analysis was performed to obtain the local stress and strain ranges and finally, the Morrow equation was applied to estimate the crack initiation lives. The results have been compared with those obtained from experimental crack growth morphology. In addition, the difference between fatigue limits for smooth specimens and spot‐welded joints for mentioned materials has been briefly discussed. It has been shown that mean stress values in the Ultra‐High Strength Steel can significantly decrease the fatigue limit of spot‐welded joint because even at very low load level the stresses exceed the yield point at the root of nugget of spot‐welded joint, while the amount of mean stress in the Mild Steel for the same load level is much less than that of Ultra‐High Strength Steel. The comparison between numerical results of fatigue crack initiation lives and experimental data provided good agreement between numerical predictions and crack growth morphology observations. The results also shows that in some cases, depending on the joint type, the life spent in the nucleation phase can be an important part of the final failure lifetime.     

The analysis of elastic-plastic adhesive stress in bonded lap joints in FRP structures

The majority of researchers who investigate the theoretical distribution of adhesive stresses in bonded lap joints assume that the adhesive behaves as a linear elastic material. While this assumption does provide useful information, for example, the intensities of stress concentrations and their locations, the results do not reflect the true stress distribution or behaviour at appreciable levels of loading. Practical joints using typical structural adhesives will incur considerable adhesive yielding as loading is increased to failure. The analysis must, therefore, include plastic yielding of the adhesive.This paper presents two analytical techniques, namely, the classical and finite element theories, which will be used to determine elastic-plastic adhesive stress distribution in bonded lap joints. The theoretical work will consider the single, double and tubular lap configurations having both similar and dissimilar adherends. Case studies will be presented to illustrate the development of adhesive yielding and to compare the different analytical techniques.The classical approach was found to be intractable to a closed form solution and consequently a numerical method was employed.     

Stresses at joints and cracks in highway and airport pavements

The weight function method is used to determine the stress intensity factors for cracks and joints in highway and airport pavements. The relationship between the stress intensity factors and the deflection caused by a wheel load are then used to obtain the stresses in the pavement. The new method that combines the theory of elasticity and fracture mechanics is called EFM. The results from EFM for the deflection and bending stress at the midslab position along the longitudinal edge are compared with the theoretical solution of Westergaard, solutions using the finite element method, and with the experimental data from the AASHO road test. The deflection caused by an axle load at the corner of a transverse joint for a rigid pavement determined by EFM is also compared with the test data from the AASHO road test. There is good agreement in all cases.     

CFRP加固钢板的粘结界面剥离破坏

II型界面破坏是碳纤维增强树脂复合材料(CFRP)加固钢板常见的破坏方式之一。为揭示CFRP加固钢板粘结界面破坏的力学机制,开展了单剪试验和双剪试验分别研究了CFRP-钢板界面力学性能及破坏过程,并采用数字图像相关技术(DIC)对CFRP的轴向应变分布进行监测。对比两个试验的破坏模式发现,双剪试件的粘结界面主要发生II型破坏,界面破坏的主要力学原因是剪应力;而存在偏心加载的单剪试件,粘结界面上的剪应力和偏心加载引起的弯矩共同作用,使粘结界面发生I/II型混合模式失效。在II型破坏模式下,不同粘结长度的极限荷载及粘结滑移值随着粘结长度的增大而增大,但当粘结长度超过有效粘结长度后,极限荷载及极限滑移值基本保持不变。而在所讨论的偏心加载引起的界面I/II型混合破坏模式下,不同粘结长度的极限荷载基本不变。基于试验数据得到的双线性粘结-滑移关系建立了有限元模型,对CFRP加固钢板的II型界面粘结破坏行为进行分析,数值模拟结果与试验结果吻合较好。      

Mechanical property and failure mechanism of 3D Carbon–Carbon braided composites bolted joints under unidirectional tensile loading

In this paper, the mechanical property and failure mechanism of Carbon–Carbon braided composites (C–Cs) bolted joints structure subjected to unidirectional tensile load were studied by the experimental method and numerical analysis. The braided C–Cs bolted joints with the single-bolt single-lap (SBS) and double-bolt single-lap (DBS) were tested. The dominant failure modes for both C–Cs SBS and DBS joint configurations were bearing failure and net-tension. Additionally, the finite element method (FEM) was utilized to study the mechanical property and failure mechanism of the joints. The FEM results have a good agreement with the test values. Parametrics studies were implemented by finite element (FE) analysis to classify the effects of geometric parameters including the joint width (W), edge distance (e) and the bolt pitch (p) on the SBS and DBS joint configurations. It can be found that present numerical model can be used to predict the experimental mechanical behaviors and failure modes of bolted C–Cs joints with different geometric parameters and joint configurations.