Mechanical analysis of bi-component-fibre nonwovens: Finite-element strategy

In thermally bonded bi-component fibre nonwovens, a significant contribution is made by bond points in defining their mechanical behaviour formed as a result of their manufacture. Bond points are composite regions with a sheath material reinforced by a network of fibres’ cores. These composite regions are connected by bi-component fibres — a discontinuous domain of the material. Microstructural and mechanical characterization of this material was carried out with experimental and numerical modelling techniques. Two numerical modelling strategies were implemented: (i) traditional finite element (FE) and (ii) a new parametric discrete phase FE model to elucidate the mechanical behaviour and underlying mechanisms involved in deformation of these materials. In FE models the studied nonwoven material was treated as an assembly of two regions having distinct microstructure and mechanical properties: fibre matrix and bond points. The former is composed of randomly oriented core/sheath fibres acting as load-transfer link between composite bond points. Randomness of material’s microstructure was introduced in terms of orientation distribution function (ODF). The ODF was obtained by analysing the data acquired with scanning electron microscopy (SEM) and X-ray micro computed tomography (CT). Bond points were treated as a deformable two-phase composite. An in-house algorithm was used to calculate anisotropic material properties of composite bond points based on properties of constituent fibres and manufacturing parameters such as the planar density, core/sheath ratio and fibre diameter. Individual fibres connecting the composite bond points were modelled in the discrete phase model directly according to their orientation distribution. The developed models were validated by comparing numerical results with experimental tensile test data, demonstrating that the proposed approach is highly suitable for prediction of complex deformation mechanisms, mechanical performance and structure-properties relationships of composites.     

含孔隙复合材料超声衰减分析的细观有限元模型

基于DIGIMAT/FE建立含孔隙复合材料细观模型,模型涵盖纤维、树脂和孔隙三相,有效反映了复合材料真实的微结构和细观材料属性,结合通用的ABAQUS/EXPLICIT对细观模型施加超声波激励。通过提取超声波在材料内传播云图,建立了单向连续纤维增强复合材料超声衰减和孔隙率的关系。以T800/环氧树脂复合材料体系为例,研究孔隙尺寸对超声衰减系数模拟结果的影响,并将数值模拟结果与解析模型得到的经验关系进行对比,验证了模型的有效性。该方法能够有效地指导实验过程,为降低复合材料孔隙率、提高其性能提供理论依据。     

A progressive damage simulation algorithm for GFRP composites under cyclic loading. Part II: FE implementation and model validation

The FE implementation of FADAS, a material constitutive model capable of simulating the mechanical behaviour of GFRP composites under variable amplitude multiaxial cyclic loading, was presented. The discretization of the problem domain by means of FE is necessary for predicting the damage progression in real structures, as failure initiates at the vicinity of a stress concentrator, causing stress redistribution and the gradual spread of damage until the global failure of the structure. The implementation of the stiffness and strength degradation models in the principal material directions of the unidirectional ply was thoroughly discussed. Details were also presented on the FE models developed, the computational effort needed and the definition of final failure considered. Numerical predictions were corroborated satisfactorily by experimental data from constant amplitude uniaxial fatigue of multidirectional glass/epoxy laminates under various stress ratios. The validation of predictions included fatigue strength, stiffness degradation and residual static strength after cyclic loading.     

Constitutive modeling of woven composites considering asymmetric/anisotropic, rate dependent, and nonlinear behavior

The mechanical performance of woven composites was analyzed focusing on their nonlinear and rate dependent asymmetric/anisotropic deformation behavior. Three key characteristics were identified which are indispensable for realistically simulating the mechanical performance of woven composites: the asymmetric material behavior between tension and compression, its anisotropic and nonlinear evolution and rate dependency. To include all three characteristics into the nonlinear finite element analysis for woven composites, a phenomenological constitutive equation was developed based on an elasto-viscoplastic theory using the modified Drucker–Prager yield criterion and, in particular, developing the anisotropic nonlinear hardening law. A characterization method using both uniaxial tensile and compressive tests at different strain rates was proposed to determine the material properties for the constitutive equation. Then, the developed constitutive equation was incorporated into a finite element code and was validated by comparing the finite element simulation of the three points bending test with experiments.     

Effect of manufacturing defects on mechanical properties and failure features of 3D orthogonal woven C/C composites

For high performance 3D orthogonal textile Carbon/Carbon (C/C) composites, a key issue is the manufacturing defects, such as micro-cracks and voids. Defects can be substantial perturbations of the ideal architecture of the materials which trigger the failure mechanisms and compromise strength. This study presents comprehensive investigations, including experimental mechanical tests, micron-resolution computed tomography (μCT) detection and finite element modeling of the defects in the C/C composite. Virtual C/C specimens with void defects were constructed based on μCT data and a new progressive damage model for the composite was proposed. According to the numerical approach, effects of voids on mechanical performance of the C/C composite were investigated. Failure predictions of the C/C virtual specimens under different void fraction and location were presented. Numerical simulation results showed that voids in fiber yarns had the greatest influences on performance of the C/C composite, especially on tensile strength.     

C/C-SiC缎纹编织复合材料孔隙缺陷的建模及其拉伸性能仿真

主要研究了随机孔隙缺陷在C/C-SiC缎纹编织复合材料中的有限元建模方法及其对拉伸性能的影响。基于C/C-SiC缎纹编织复合材料的细观结构和实验观察所得的微观形貌,得出孔隙缺陷具有随机分布特征,提出了一种三维随机碰撞算法模拟孔隙在复合材料中的分布,建立了含随机孔隙缺陷的C/C-SiC缎纹编织复合材料的有限元模型。采用有限元软件ABAQUS模拟了其在拉伸载荷下的力学行为,讨论了孔隙缺陷的尺寸和分布形式对材料拉伸性能的影响,并对试样进行了单轴拉伸实验测试,验证了数值模拟的有效性。结果表明,用本文方法建立的有限元模型符合含孔隙缺陷C/C-SiC缎纹编织复合材料的真实细观结构,相应的数值模拟结果也与试验数据吻合较好。本文的研究结果为含孔隙缺陷的缎纹编织复合材料及具有相似结构特征的复合材料的力学分析与优化设计提供了一种有效的方法。      

Tensile stress–crack width law for steel fibre reinforced self-compacting concrete obtained from indirect (splitting) tensile tests

In this work, mode I fracture parameters of steel fibre reinforced self-compacting concrete (SFRSCC) were derived from the numerical simulation of indirect splitting tensile tests. The combined experimental and numerical research allowed a comparison between the stress–crack width (σ–w) relationship acquired straightforwardly from direct tensile tests, and the σ–w response derived from inverse analysis of the splitting tensile tests results. For this purpose a comprehensive nonlinear 3D finite element (FE) modeling strategy was developed. A comparison between the experimental results obtained from splitting tensile tests and the corresponding FE simulations confirmed the good accuracy of the proposed strategy to derive the σ–w law for these composites. It is concluded that the post-cracking tensile laws obtained from inverse analysis provided a close relationship with the ones obtained from the experimental uniaxial tensile tests.     

含缺陷平纹机织复合材料拉伸力学行为数值模拟

基于平纹机织复合材料的细观结构单胞模型, 考虑其制备过程中产生的孔隙缺陷为随机分布的特征, 通过引入两参数Weibull分布函数, 应用Python语言实现了ABAQUS的二次开发, 并采用Linde等提出的失效准则, 建立了含孔隙缺陷平纹机织复合材料的渐进损伤模型, 利用有限元数值方法模拟了其拉伸应力-应变行为, 针对该模型, 讨论了孔隙缺陷对材料拉伸应力-应变行为的影响, 并阐述了该平纹机织复合材料单胞模型在经向拉伸载荷作用下其纤维束的损伤及演化过程。结果表明, 该模型给出的数值模拟结果与实验数据吻合较好, 证明了模型的有效性, 为该类材料的优化设计及其力学性能分析提供了一种有效方法。      

Effects of Process-Induced Voids on the Properties of Fibre Reinforced Composites

It is well known that voids have detrimental effects on the performance of composites. This study aims to provide a practical method for predicting the effects of process induced voids on the properties of composites. Representative volume elements(RVE) for carbon ?bre/epoxy composites of various ?bre volume fractions and void contents are created, and the moduli and strengths are derived by ?nite element analysis(FEA). Regression models are ?tted to the FEA data for predicting composite properties including tensile, compressive and shear. The strengths of composite laminates including tensile strength and interlaminar shear strength(ILSS) are calculated with the aid of the developed models. The model predictions are compared with various experimental data and good agreement is found. The outcome from this study provides a useful optimisation and robust design tool for realising affordable composite products when process induced voids are taken into account.     

Determining the minimum,critical and maximum fibre content for twisted yarn reinforced plant fibre composites

The effect of fibre volume fraction on the physical and tensile properties of aligned plant fibre composites (PFCs) produced via vacuum infusion has been investigated. There is no clear correlation between fibre volume fraction and porosity. However, low fibre content PFCs are prone to intra-yarn voids, while high fibre content PFCs are prone to inter-yarn voids. This is due to changing resin flow dynamics with increasing fibre content.     

Nonlinear constitutive models for FRP composites using artificial neural networks

This paper presents a new approach to generate nonlinear and multi-axial constitutive models for fiber reinforced polymeric (FRP) composites using artificial neural networks (ANNs). The new nonlinear ANN constitutive models are complete and have been integrated with displacement-based FE software for the nonlinear analysis of composite structures. The proposed ANN constitutive models are trained with experimental data obtained from off-axis tension/compression and pure shear (Arcan) tests. The proposed ANN constitutive model is generated for plane–stress states with assumed functional response in some parts of the multi-axial stress space with no experimental data. The ability of the trained ANN models to predict material response is examined directly and through FE analysis of a notched composite plate. The experimental part of this study involved coupon testing of thick-section pultruded FRP E-glass/polyester material. Nonlinear response was pronounced including in the fiber direction due to the relatively low overall fiber volume fraction (FVF). Notched composite plates were also tested to verify the FE, with ANN material models, to predict general non-homogeneous responses at the structural level.     

Effective behavior of porous elastomers containing aligned spheroidal voids

The theoretical need to recognize the link between the basic microstructure of nonlinear porous materials and their macroscopic mechanical behavior is continuously rising owing to the existing engineering applications. In this regard, a semi-analytical homogenization model is proposed to establish an overall, continuum-level constitutive law for nonlinear elastic materials containing prolate/oblate spheroidal voids undergoing finite axisymmetric deformations. The microgeometry of the porous materials is taken to be voided spheroid assemblage consisting of confocally voided spheroids of all sizes having the same orientation. Following a kinematically admissible deformation field for a confocally voided spheroid, which is the basic constituent of the microstructure, we make use of an energy-averaging procedure to obtain a constitutive relation between the macroscopic nominal stress and deformation gradient. In this work, both prolate and oblate voids are considered. As a numerical example, we study macroscopic nominal stress components for a hyperelastic porous material consisting of a neo-Hookean matrix and prolate/oblate voids subjected to 3-D and plane strain dilatational loadings. In this numerical study, the relation between the relevant microstructural variables (i.e., initial porosity and void aspect ratio) for a rather large range of applied stretch is put into evidence for two types of loading. Finally, a finite element (FE) simulation is presented, and the homogenization model is assessed through comparison of its predictions with the corresponding FE results. The illustrated agreement between the results demonstrates a good accuracy of the model up to rather large deformations.     

Air voids reduction phenomena of asphalt concrete – A continuum approach

Asphalt concrete used in flexible highway pavement construction has 5–8 percent air voids immediately after laying of the roadway. Constitutive laws for asphalt concrete developed till now have modelled the mix as a linear elastic or viscoelastic material and have not taken into account the effect of void concentration on the mechanical behaviour of the material. In this paper, the theory of linear elastic material with voids is used to model asphalt concrete under isothermal conditions. Two cases of void reduction behaviour are studied, one in which the void volume reduces asymptotically under a constant load and the other in which it reaches the refusal air void content. The model is used to predict the creep behaviour under constant compressive stress as well as to obtain the hysteretic stress-strain behaviour. Solutions for the case of uniaxial deformation are derived and the strains are simulated for a constant compressive stress. Use of the air voids reduction measure as a possible damage parameter is also examined. This revised version was published online in July 2006 with corrections to the Cover Date.     

平纹编织SiC/SiC复合材料多尺度建模及强度预测

连续SiC纤维增强SiC基体复合材料（SiC/SiC）具有优异的高温力学性能、辐照稳定性及较低的氚渗透率,在核工程结构领域具有良好的应用前景,掌握其承载状态下的损伤演化和强度性能,对SiC/SiC复合材料的应用具有重要指导意义。本文基于平纹编织SiC/SiC复合材料的制备过程和组分材料分布的多尺度特性,考虑复合材料微观结构的局部近似周期性,建立了纤维丝尺度和纤维束尺度单胞模型。使用有限元分析软件对纤维丝尺度模型的弹性性能和强度性能进行预测,将这些性能参数代入纤维束尺度模型,引入Tsai-Wu失效准则,根据材料的不同失效模式并对失效单元进行方向性刚度折减,模拟了平纹编织SiC/SiC复合材料在单轴拉伸载荷下的渐进损伤过程。数值模拟曲线与试验曲线吻合较好,实现了对平纹编织SiC/SiC复合材料强度的有效预测。      

Finite element modeling of ballistic impact on multi-layer Kevlar 49 fabrics

This paper presents a material model suitable for simulating the behavior of dry fabrics subjected to ballistic impact. The developed material model is implemented in a commercial explicit finite element (FE) software LS-DYNA through a user defined material subroutine (UMAT). The constitutive model is developed using data from uniaxial quasi-static and high strain rate tension tests, picture frame tests and friction tests. Different finite element modeling schemes using shell finite elements are used to study efficiency and accuracy issues. First, single FE layer (SL) and multiple FE layers (ML) were used to simulate the ballistic tests conducted at NASA Glenn Research Center (NASA-GRC). Second, in the multiple layer configuration, a new modeling approach called Spiral Modeling Scheme (SMS) was tried and compared to the existing Concentric Modeling Scheme (CMS). Regression analyses were used to fill missing experimental data – the shear properties of the fabric, damping coefficient and the parameters used in Cowper-Symonds (CS) model which account for strain rate effect on material properties, in order to achieve close match between FE simulations and experimental data. The difference in absorbed energy by the fabric after impact, displacement of fabric near point of impact, and extent of damage were used as metrics for evaluating the material model. In addition, the ballistic limits of the multi-layer fabrics for various configurations were also determined.     

Numerical modelling of the effects of elevated service temperatures on the debonding process of FRP-to-concrete bonded joints

There are many issues concerning the performance behaviour of FRP-to-concrete interfaces at elevated service temperatures (EST). At EST, i.e. slightly above the glass transition temperature (T_g), some properties associated with the FRP composites, such as the stiffness, strength or the bond characteristics, degrade. This is a crucial issue and there are only a few studies that take into account such effects on FRP-to-concrete interfaces at EST. This paper examines, through a numerical analysis, the performance of FRP-to-concrete bonded joints at EST using a new discrete model based on truss elements and shear springs. The External Bonded Reinforcement (EBR) systems subjected to EST are analyzed. The numerical discrete model was implemented in a MATLAB routine and the bond–slip curves of the interfaces at EST were obtained from a model found in literature. The numerical results revealed that the interface at EST behaves similarly to one with two equal mechanical loads applied at both ends of the FRP plate. The load–slip curves or bond stresses, strains or slippages along the bonded length obtained from several bond–slip curves at different temperatures were obtained. Two different single-lap shear tests were simulated at steady-state (steady temperature followed by load increase) and transient state (steady load followed by temperature increase). Regarding the influence of the temperature on the adhesion between the FRP and concrete, the results showed that an increase in the temperature at an earlier situation, i.e. during a period where temperature had no influence in the concrete deformations, leads to an increase in the effective bond length of the interface affecting the initial strength of the interface.     

A modified pull-out test for bond of near-surface mounted FRP rods in concrete

Among the strengthening techniques based on fiber-reinforced polymer (FRP) composites, the use of near-surface mounted (NSM) FRP rods is emerging as a promising technology for increasing flexural and shear strength of deficient concrete, masonry and timber members. In order for this technique to perform effectively, bond between the NSM reinforcement and the substrate material is a critical issue. Aim of this project was to investigate the mechanics of bond between NSM FRP rods and concrete, and to analyze the influence of the most critical parameters on the bond performance. Following up to previous investigations, a different type of specimen was designed in order to obtain a test procedure as efficient and reliable as possible. Among the investigated variables were: type of FRP rod (material and surface pattern), groove-filling material, bonded length, and groove size. Results of the first phase of the project are presented and discussed in this paper.     

Approximate limit analysis of full scale FRP-reinforced masonry buildings through a 3D homogenized FE package

A 3D homogenized FE limit analysis software for the numerical prediction of collapse loads and failure mechanisms of entire masonry buildings reinforced with FRP strips is presented. In particular, a two steps approach is adopted: in step I, masonry homogenized failure surfaces are obtained through an admissible kinematic FE approach in the representative element of volume (REV), constituted by a brick interconnected with its six neighbors with finite thickness mortar joints. 8-Noded rigid infinitely resistant parallelepiped elements interconnected with interfaces with frictional behavior and limited tensile and compressive strength are utilized to model the REV. A simple linear programming problem in few variables is obtained, suitable to recover numerically masonry failure surfaces when loaded in- and out-of-plane. In step II, homogenized failure surfaces are implemented in the novel FE kinematic limit analysis software for an inexpensive evaluation of collapse loads of entire buildings. Delamination is considered in the model imposing to FRP–masonry interfaces a limited resistance in agreement with Italian code CNR-DT-200. 6-Noded rigid infinitely resistant 3D wedge-shaped elements are used to model homogenized masonry, whereas FRP strips are modeled by means of triangular 3-noded rigid elements.     

An experimental and numerical study of the effects of length scale and strain state on the necking and fracture behaviours in sheet metals

Within sheet metal forming, crashworthiness analysis in the automotive industry and ship research on collision and grounding, modelling of the material failure/fracture, including the behaviour at large plastic deformations, is critical for accurate failure predictions. In order to validate existing failure models used in finite element (FE) simulations in terms of dependence on length scale and strain state, tests recorded with the optical strain measuring system ARAMIS have been conducted. With this system, the stress–strain behaviour of uniaxial tensile tests was examined locally, and from this information true stress–strain relations were calculated on different length scales across the necking region. Forming limit tests were conducted to study the multiaxial failure behaviour of the material in terms of necking and fracture. The failure criteria that were verified against the tests were chosen among those available in the FE software Abaqus and the Bressan–Williams–Hill (BWH) criterion proposed by Alsos et al, 2008. The experimental and numerical results from the tensile tests confirmed that Barba's relation is valid for handling stress–strain dependence on the length scale used for strain evaluation after necking. Also, the evolution of damage in the FE simulations was related to the processes ultimately leading to initiation and propagation of a macroscopic crack in the final phase of the tensile tests. Furthermore, numerical simulations using the BWH criterion for prediction of instability at the necking point showed good agreement with the forming limit test results. The effect of pre-straining in the forming limit tests and the FE simulations of them is discussed.     

基于三维流场模型的含孔隙复合材料弹性常数有限元预测模型

为预测含孔隙复合材料单向层合板的有效弹性常数, 基于孔隙周边纤维分布和形态与三维Rankine椭圆体绕流流场的相似性, 提出了一种基于三维Rankine椭圆体绕流流场比拟的含孔隙复合材料弹性常数计算模型与方法。建立了含孔隙复合材料的有限元单胞计算模型, 用流场的速度变化比拟单胞内纤维体积分数的变化, 用流线形状比拟孔隙周边纤维的形态。通过对单胞施加周期性边界条件, 结合孔隙形态的概率分布模型和刚度平均法, 计算了含孔隙复合材料单向层合板的弹性常数。计算结果与实验数据有较好的一致性, 数值计算可以有效反映孔隙对复合材料单向层合板弹性常数的影响。