Circular braiding take-up speed generation using inverse kinematics

Circular overbraiding of composite preforms on complex mandrels currently lacks automatic generation of machine control data. To solve this limitation, an inverse kinematics-based procedure was designed and implemented for circular braiding machines with optional guide rings, resulting in a take-up speed profile for a given braid angle distribution on mandrels with complex 3D shapes including non-axisymmetric, optionally eccentric cross-sections that can vary in shape and size along an optionally curved mandrel centerline, allowing a curved machine movement. This procedure reduces the problem size, resulting in a short computation time, fit for CAE process chain integration. Numerical control data was generated for a complex mandrel with a specified braid angle and a triaxial braid. A simulation using this control data yields a braid angle that deviates a few degrees from the specified braid angle. The simulation was validated experimentally, using the generated instructions to control the braiding machine. This showed a deviation from the simulated braid angle of 3 degrees in the centered, non-tapered mandrel regions, up to 10 degrees in tapered regions and an experimental scatter of 7 degrees. The deviation is mainly attributed to the neglect of yarn interaction and guide ring contact friction in the model, leading to an incorrectly modeled convergence zone length.     

Finite element simulation of the braiding process for arbitrary mandrel shapes

An approach to simulate the two-dimensional braiding process using a commercial explicit finite element software is presented. Preforms with generic shapes are analyzed. A procedure is given to determine the boundary conditions of the braiding mandrel including the extraction of necessary geometry information. The friction coefficients needed as input parameters are determined in separate tests. The simulation results are processed with an algorithm that derives the braiding angle and the axial spacing of the yarns. For validation, a generic mandrel geometry is overbraided and a method to compare simulation and experiment is presented. The preform is analyzed using an optical sensor. The measurements are filtered and averaged. The simulation model is validated by comparing the braiding angle of simulation and experiment. A good agreement between simulation and experimental results is achieved.     

A new indentation model for sandwich circular panels with gradient metallic foam cores

A new analytical model is presented to predict indentation behavior of the sandwich circular panel with gradient foam cores under a flat-end cylindrical indenter. In the model, a displacement field of the upper face sheet of the sandwich panel is assumed to be a cosine function and plateau stress of the gradient foam core varies with the mass density along the thickness direction of the sandwich panel. The sandwich panel is modeled as an infinite, isotropic, plastic membrane on a rigid-plastic foundation. The explicit solutions of the relation between the indentation force and maximum plastic regions of the upper face sheet are derived based on the principle of minimum work. The analytical results are validated using the finite element code ABAQUS^®. The influences of the gradient foam core on the maximum plastic region, the indentation force and the plastic strain energy of the sandwich panel are also investigated.     

Finite element analyses on transverse impact behaviors of 3-D circular braided composite tubes with different braiding angles

This paper presents finite element analyses (FEA) on the transverse impact responses of 3-D circular braided composite tubes with the braiding angles of 15°, 30° and 45°. A finite element model of the braided composite tube was established at microstructure level to analyze the transverse impact behaviors. From the FEA results, the impact damage, deformation and stress distribution were obtained to analyze the damage mechanism. Stress propagation in lower braiding angle tubes was faster than that of the higher braiding angle. The impact responses of the braided composite tubes were also tested to obtain load–displacement curves and energy absorption for the comparisons with the FEA results. The impact damage and fracture morphology obtained from the FEA were in good agreement with the experimental results, which demonstrated the feasibility of the FEA model for the design of the braided tube.     

A size-dependent third-order shear deformable plate model incorporating strain gradient effects for mechanical analysis of functionally graded circular/annular microplates

In this paper, we develop a novel size-dependent plate model for the axisymmetric bending, buckling and free vibration analysis of functionally graded circular/annular microplates based on the strain gradient elasticity theory. The displacement field is chosen by using a refined third-order shear deformation theory which assumes that the in-plane and transverse displacements are partitioned into bending and shear components and satisfies the zero traction boundary conditions on the top and bottom surfaces of the microplate. Besides, the present model contains three material length scale parameters to capture the size effect. The material properties of the microplate are assumed to vary in the thickness direction and estimated through the classical rule of mixture. By using Hamilton's principle, the equations of motion and boundary conditions are obtained. Afterward, the differential quadrature method is adopted to discretise the governing differential equations along with various types of edge supports and therefore the deflection, critical buckling load and natural frequency can be determined. Convergence and comparison studies are carried out to establish the reliability and accuracy of the numerical results. Finally, a parametric study is conducted to investigate the influences of material length scale parameters, gradient index, thickness-to-outer radius ratio, outer-to-inner radius ratio and boundary conditions on the mechanical characteristics of the microplate.     

Structural optimisation of random discontinuous fibre composites: Part 2 – Case study

This is the second paper in a two part series presenting the development of a stiffness optimisation algorithm to intelligently optimise the fibre architecture of discontinuous fibre composites. A Multi-Criteria Decision Making (MCDM) strategy is used to select parameters associated with the fibre architecture, to produce components that satisfy stiffness, cost and mass criteria.The model has been successfully demonstrated using an automotive spare wheel well geometry, which shows that a highly optimised discontinuous fibre composite solution can compete against a continuous fabric counterpart in terms of specific stiffness, whilst presenting an opportunity for significant cost reduction. This could potentially lead to the application of composite materials into new areas where cost has previously been prohibitive.     

Torsion of functionally graded nonlocal viscoelastic circular nanobeams

The elastostatic problem of functionally graded circular nanobeams under torsion, with nonlocal elastic behavior proposed by Eringen, is preliminarily formulated. Exact solutions are detected for nanobeams with arbitrary axial gradations of elastic properties and radially quadratic distributions of shear moduli. Extension of the treatment to nonlocal viscoelastic composite circular nanobeams is then performed. An effective solution procedure based on Laplace transform is developed, providing a new correspondence principle in nonlocal viscoelasticity for functionally graded materials. Displacements, shear strains and stresses are established for nonlocal viscoelastic nanobeams made of periodic fiber-reinforced materials, with polymeric matrix described by a Maxwell model connected in series with a Voigt model.     

Unit yarn-reduction technique and flexural properties of tapered composites based on four-step row and column braiding

Mechanisms of unit yarn-reduction braiding were investigated and preform microstructures were characterized by digital image photography and topological analysis. Flexural properties and failure mechanisms of the unit yarn-reduction composites, cut composites and uniform composites were compared. Results indicated that continuity of the braiding process must be ensured after yarn reduction and distribution of the reduction units should be uniform. A smoothly trapezoidal profile appeared near the unit yarn-reduction cross-section and braiding angles and yarn lengths in the surface or interior yarn-reduction control volumes all increased. Flexural properties of the unit yarn-reduction composites were significantly higher than those of the cut composites and slightly lower than the uniform composites. The damage process of the yarn-reduction composites can be divided into the initial, developing and serious damage stages with yarn breakage being the dominant failure mechanism, while the primary failure mechanisms of the cut composites were matrix microcracking and fiber pulling-out.     

A composite cost model for the aeronautical industry: Methodology and case study

This paper presents a novel composite production cost estimation model. The strength of the model is its modular construction, allowing for easy implementation of different production methods and case studies. The cost model is exemplified by evaluating the costs of a generic aeronautical wing, consisting of skin, stiffeners and rib feet. Several common aeronautical manufacturing methods are studied. For studied structure, hand layup is the most cost-effective method for annual volumes of less than 150 structures per year. For higher production volumes automatic tape layup (ATL) followed by hot drape forming (HDF) is the most cost-effective choice.     

Passive and SMA-activated confinement of circular masonry columns with basalt and glass fibers composites

Fiber Reinforced Polymer (FRP) composites are widely used for strengthening and conservation of historic masonry, even if research problems are still open. The mechanical behavior of masonry columns having a circular cross section, confined with glass and basalt FRP systems was studied in this paper. An extended experimental investigation is presented in order to show the results of axial compression tests on circular masonry columns built with natural blocks (calcareous stone). Active confinement was also studied by using a novel technique that employs Shape Memory Alloys (SMA). Totally twenty-four masonry columns were built, instrumented and tested. Different fibers, strengthening schemes and matrix/adhesive were used for the confinement of the columns.Unstrengthened columns were tested as reference specimens. Axial strain of the columns and tensile strain of the fibers in the direction perpendicular to the primary axis of the columns were measured with the applied load. Experimental results revealed the effectiveness of the FRP-confinement for masonry columns. Active confinement was found to be effective at early loading stages since an increased stiffness of the SMA/GFRP-confined columns was measured.A prediction of the compressive strength was obtained by using the model of the Italian guidelines CNR DT 200 (National Research Council) in order to compare the experimental results with the design approach, also for new types of fiber like basalt which were not included in the technical codes. Finally, the experimental results were compared with theoretical values calculated according with to two existing analytical models in order to test their effectiveness for the analyzed configurations.     

Influence of in-plane pre-load on the vibration frequency of circular graphene sheet via nonlocal continuum theory

In this study, the free vibration behavior of circular graphene sheet under in-plane pre-load is studied. By using the nonlocal elasticity theory and Kirchhoff plate theory, the governing equation is derived for single-layered graphene sheets (SLGSs). The closed-form solution for frequency vibration of circular graphene sheets under in-plane pre-load has been obtained and nonlocal parameter appears into arguments of Bessel functions. The results are subsequently compared with valid result reported in the literature. The effects of the small scale, pre-load, mode number and boundary conditions on natural frequencies are investigated. The results are shown that at smaller radius of circular nanoplate, the effect of in-plane pre-loads is more importance.     

FRP reinforced/prestressed concrete members: A torsional design model

The torsional design provisions of the Canadian standard S806 for fiber reinforced polymer (FRP) reinforced (RC) or prestressted (PC) concrete members are presented and their theoretical and empirical justifications are provided. The key parameters governing the nominal torsional strength are identified and their appropriate values for FRP-RC/PC members are specified. The accuracy of the method is evaluated by analyzing 27 FRP-RC/PC members tested under pure torsion by other investigators. The CSA method is able to reasonably predict the torsional strength of these beams. It is also shown that the cracking torque can be predicted using the formulas in the ACI and AASHTO LRFD codes without any modification. Some considerations with the statements of CNR-DT 203, fib 40, JSCE guidelines are also carried out.     

A model for fiber length attrition in injection-molded long-fiber composites

Long-fiber thermoplastic (LFT) composites consist of an engineering thermoplastic matrix with glass or carbon reinforcing fibers that are initially 10–13 mm long. When an LFT is injection molded, flow during mold filling degrades the fiber length. Here we present a detailed quantitative model for fiber length attrition in a flowing fiber suspension. The model tracks a discrete fiber length distribution at each spatial node. A conservation equation for total fiber length is combined with a breakage rate that is based on buckling of fibers due to hydrodynamic forces. The model is combined with a mold filling simulation to predict spatial and temporal variations in fiber length distribution in a mold cavity during filling. The predictions compare well to experiments on a glass–fiber/PP LFT molding. Fiber length distributions predicted by the model are easily incorporated into micromechanics models to predict the stress–strain behavior of molded LFT materials.     

Structural optimisation of random discontinuous fibre composites: Part 1 – Methodology

This paper presents a finite element model to optimise the fibre architecture of components manufactured from discontinuous fibre composites. An optimality criterion method has been developed to maximise global component stiffness, by determining optimum distributions for local section thickness and preform areal mass. The model is demonstrated by optimising the bending performance of a flat plate with three holes. Results are presented from a sensitivity study to highlight the level of compromise in stiffness optimisation caused by manufacturing constraints associated with the fibre deposition method, such as the scale of component features relative to the fibre length.     

Development,characterization and analysis of auxetic structures from braided composites and study the influence of material and structural parameters

Auxetic materials are gaining special interest in technical sectors due to their attractive mechanical behaviour. This paper reports a systematic investigation on missing rib design based auxetic structures produced from braided composites for civil engineering applications. The influence of various structural and material parameters on auxetic and mechanical properties was thoroughly investigated. The basic structures were also modified with straight longitudinal rods to enhance their strengthening potential in structural elements. Additionally, a new analytical model was proposed to predict Poisson’s ratio through a semi empirical approach. Auxetic and tensile behaviours were also predicted using finite element analysis. The auxetic and tensile behaviours were observed to be more strongly dependent on their structural parameters than the material parameters. The developed analytical models could well predict the auxetic behaviour of these structures except at very low or high strains. Good agreement was also observed between the experimental results and numerical analysis.     

Modeling,processing, and characterization of exfoliated graphite nanoplatelet-nylon 6 composite fibers

We present theoretical and experimental studies on the effects of platelet-like filler orientation on the mechanical properties of melt-spun exfoliated graphite nanoplatelet(xGnP)-nylon 6(PA6) composite fibers. In numerical studies, the Mori–Tanaka micromechanics model was employed to formulate analytical models to predict the mechanical properties of xGnP-PA6 composite fibers with varying xGnP orientations in a three-dimensional spatial domain. Simulation results showed that the predicted properties of xGnP-PA6 composite fibers were highly affected by xGnP orientation and were correlated with the measured properties of composite fibers treated with varying draw ratios. The tensile moduli of composite fibers at varying xGnP contents showed significant improvements, which is attributed to the drawing-induced alignment of PA6 molecular chains as well as the alignment of xGnPs. Both as-received and acid-treated xGnPs were incorporated in PA6, and mechanical test results suggested that acid-treated xGnPs provide stronger interfacial bonding with PA6.     

Harsh environments effects on the axial behaviour of circular concrete-filled fibre reinforced-polymer (FRP) tubes

Concrete-filled fibre-reinforced polymer (FRP) tubes (CFFTs) are becoming an attractive system for structural elements proposed to harsh environments. FRP tube provides a corrosion resistant element, reinforcement, confinement for the concrete core, and a stay-in-place formwork. Harsh environments may affect the mechanical performance of the FRP tube, which consequently affect the structural response of the CFFT members. This project investigates the environmental degradation and the durability of concrete cylinders unconfined and confined by filament-wound glass-FRP tubes. Standard plain concrete cylinders and CFFT cylinders were immersed in pure water, salt and alkaline solutions, and exposed to 200 freeze–thaw cycles, between −40 °C and +40 °C. Then, the cylinders were tested under uniaxial compression test to evaluate their performance by comparing the stress–strain behaviour and their ultimate load capacities. Test results indicated that the FRP tube, in CFFTs, is significantly qualified as a sustainable coating material to resist the harsh environments attacks. Theoretical predictions using long term confinement models from CSA and ACI codes are presented.     

Characteristic impact resistance model analysis of cellulose nanofibril-filled polypropylene composites

Notched and unnotched Izod impact strength of cellulose nanofibers (CNFs) and microfibrillated cellulose (MFC)-filled impact modified polypropylene (PP) composites were measured and compared with microcrystalline cellulose (MCC)-filled composites. An Izod impact fracture initiation resistance theory was formulated and a characteristic impact resistance model was developed to evaluate the unique impact characteristics of cellulose nanofibril-filled PP composites. As filler loading increased CNF and MFC-filled composites showed higher characteristic impact resistance than MCC-filled ones. Among the cellulose fillers used in this study, CNF were found to be the most resistant of the three materials tested in terms of characteristic impact resistance. Even though impact resistance in not the only evaluation tool, characteristic impact resistance is an evaluation tool used to determine the material’s unique and hidden impact characteristics. The characteristic impact resistance model is useful for analysis of the impact behavior of any polymer composite material. It was also found that impact modified PP used in this study is more fracture resistant, but more crack sensitive, than conventional PP.     

Percolation model of reinforcement efficiency for carbon nanotubes dispersed in thermoplastics

Considerable experimental work on carbon nanotube-reinforced composites has shown that the reinforcement efficiency of carbon nanotubes (CNTs) becomes lower than the theoretical expectation when CNT content reaches a critical value. This critical volume fraction (percolation threshold) is considered related to the formation of percolating network. In this work, a percolation model is proposed to describe the observed sharp decrease in the reinforcement efficiency of multiwalled CNTs (MWCNTs) dispersed in thermoplastics when the CNT content exceeds the percolation threshold. The percolation threshold is estimated via a numerical simulation of randomly curved CNTs according to the statistics on geometrical features of real CNTs. The percolation model, integrated into the Halpin–Tsai equations, is verified using the experimental data of various thermoplastic composites reinforced with MWCNTs. The developed mechanical model achieves a good agreement with the measured moduli of nanocomposites, and demonstrates an excellent prediction capability over a wide range of CNT content.     

Refined and generalized hybrid type quasi-3D shear deformation theory for the bending analysis of functionally graded shells

The closed-form solution of a generalized hybrid type quasi-3D higher order shear deformation theory (HSDT) for the bending analysis of functionally graded shells is presented. From the generalized quasi-3D HSDT (which involves the shear strain functions “f(ζ)” and “g(ζ)” and therefore their parameters to be selected “m” and “n”, respectively), infinite six unknowns' hybrid shear deformation theories with thickness stretching effect included, can be derived and solved in a closed-from. The generalized governing equations are also “m” and “n” parameter dependent. Navier-type closed-form solution is obtained for functionally graded shells subjected to transverse load for simply supported boundary conditions. Numerical results of new optimized hybrid type quasi-3D HSDTs are compared with the first order shear deformation theory (FSDT), and other quasi-3D HSDTs. The key conclusions that emerge from the present numerical results suggest that: (a) all non-polynomial HSDTs should be optimized in order to improve the accuracy of those theories; (b) the optimization procedure in all the cases is, in general, beneficial in terms of accuracy of the non-polynomial hybrid type quasi-3D HSDT; (c) it is possible to gain accuracy by keeping the unknowns constant; (d) there is not unique quasi-3D HSDT which performs well in any particular example problems, i.e. there exists a problem dependency matter.