Modeling of delamination using a discretized cohesive zone and damage formulation

Delamination initiation and growth are analyzed by using a discrete cohesive crack model. The delamination is constrained to grow along a tied interface. The model is derived by postulating the existence of a maximum load surface which limits the adhesive forces in the process zone of the crack. The size of this maximum load surface is made dependent on the amount of dissipated crack opening work, such that the maximum load surface shrinks to zero as a predefined amount of work is consumed. A damage formulation is used to reduce the adhesive forces. Mode I, II and III loading or any combined loading is possible. An analytical solution is obtained for a single mode opening and the implications of this result on the governing equations is discussed. The delamination model is implemented in the finite element code LS-DYNA and simulation results are shown to be in agreement with experimental results.     

Crack kinking of a delamination at an inclined core junction interface in a sandwich beam

The paper considers a general interface delamination and crack kinking from an inclined core junction in a sandwich beam. This particular problem is relevant for a newly developed peel-stopper component for sandwich structures.A finite element model (FEM) was developed and calibrated against a known model by He and Hutchinson. The numerically and analytically determined solution coefficients were in a perfect agreement with each other, so the necessary generalisation of results can be obtained through the application of FEM-analyses. The FE-model was used to determine solution coefficients for a number of interface compositions of practical interest. As expected some of the coefficients were quite sensitive to the specific material combination, which confirms that accurate solution strategies are important.The solution coefficients obtained were further applied to the analysis of the crack propagation and kinking process in three different sandwich beam configurations, each of which contained an inclined junction of 20°, 30°, or 40°. The objective was to examine how the core junction angle and the fracture mechanical properties of the sandwich components influenced the crack kinking tendency. The latter is vital for the design and functionality of a newly developed peel-stopper. It was shown that smaller core junction angles will lead to longer crack propagation (delamination) along the core-core interface prior to a possible kinking. The physical insight obtained is essential for optimal design of peel-stoppers.     

Dynamic delamination fracture toughness of a graphite/epoxy laminate under impact

Dynamic delamination fracture toughness in a [90/0]_5s T300/934 graphite/epoxy laminate was investigated using impact loading. Delamination cracks of three different sizes were embedded at the mid-plane of the composite specimen. The threshold impact velocity that causes propagation of the delamination crack was used in the dynamic analysis with the finite element method. From the finite element solution, the time-history of the strain energy release rate was calculated. The critical strain energy release rate was taken to equal the maximum value of the response history.     

An analysis of delamination behaviour

Laminated composites can be damaged by foreign object impacts that produce a subsurface delamination. Under certain loading conditions these delaminations can grow and ultimately produce structural failure. In this study it was found that delamination growth results from crack propagation that depends on the stress field at the crack front produced by buckling of the delaminated section. This result was confirmed by three independent analyses. First was the development of an analytical model based on buckling and classical fracture mechanics. Second was the development and solution of a finite element model of the crack front. Third was an experimental study of laminated aluminum sheets with a well-defined delamination.     

FINITE ELEMENT ANALYSIS OF DELAMINATION CRACKS IN BENDING OF CROSS-PLY LAMINATES

SUMMARY

A study of delamination crack growth due to bending in cross-ply laminates is presented. For the understanding of interlaminar fracture behaviour of laminated composites the modelling of delamination crack growth induced by bending and shear cracks in three point bending specimens is carried out. A plane strain two-dimensional (2-D) finite element analysis is used to determine the strain energy release rates during delamination of the laminated beam. Contact elements were used to prevent the material interpenetration on the crack surfaces. The solution of the contact problem taking into account friction along crack surfaces is obtained. Energy release rates G_I and G_II for Mode I and Mode II fracture are calculated by virtual crack closure integral (VCCI) methods. Comparison of total energy release rates, obtained by local energy methods, with an analytical solution based on the beam theory and a global energy method have been carried out. Good agreement of the results obtained by various methods have been observed. Comparison of the results obtained by the solution of the contact problem and without contact elements have been performed. Significant differences between the values of energy release rates obtained with and without using contact elements have been observed. The influence of the coefficient of friction on the energy release rates is insignificant.     

Delamination of layered structures on elastic foundation

This study presents an interface fracture mechanics analysis of delamination of a layered beam resting on a Winkler elastic foundation subject to general mechanical loads. A crack tip element on elastic foundation model is established first, through which, two concentrated forces existing at the crack tip are determined in closed-form. Then total energy release rate of the crack can be expressed in term of these two forces. By using available numerical results in the literature, the phase angle of the total energy release rate is also obtained. To verify the validity and accuracy of the solutions, debonding of a bonded overlay from the base structure resting on a Winkler elastic foundation is analyzed using the present solution. Comparisons with the baseline results obtained by finite element analysis suggest that the present analytical solution provides an excellent estimation of the total energy release rate and its phase angle for interface cracks in layered structure on elastic foundation. This study provides an approximated analysis of the debonding of a thin overlay debonding from the concrete pavement, where the effect of the base structure is simplified by a Winkler elastic foundation. This solution can also be used to analyze other similar delamination problems, such as local delamination in laminated composites, and face sheet delimitation in sandwich beams.     

A method for testing interlaminar dynamic fracture toughness of polymeric composites

Static and dynamic Mode I delamination fracture in two polymeric fiber composites was studied using a WIF test method. The dynamic test was conducted on a Split Hopkinson Pressure Bar apparatus. Crack speeds up to 1000 m/s were achieved. Dynamic fracture and crack propagation were modeled by the finite element method. Dynamic initiation fracture toughness of S2/8552 and IM7/977-3 composites were obtained. The dynamic fracture toughness of IM7/977-3 associated with the high speed propagating crack was extracted from the finite element simulation based on the measured data. It was found that the dynamic fracture toughness of the delamination crack propagating at a speed up to 1000 m/s approximately equals the static fracture toughness.     

Application of virtual crack closure integral method for interface cracks in low-k integrated circuit devices under thermal load

The virtual crack closure integral (VCCI) method is used to evaluate the stress intensity factor (SIF) and energy release rate (ERR) of an interface crack under thermal load. The VCCIs used in this work include the traditionally known “Mode I” and “Mode II” VCCIs and an additional coupling VCCI. The singularity element is used in the finite element method (FEM) implementation. The SIF and ERR calculated by the FEM are compared to the exact solution in the case of a joint dissimilar semi-infinite plates with double edge crack under thermal loading. The FEM result agrees well with the exact solution for relatively coarse meshes. The contribution of the mesh density and material mismatch to the FEM error is also explored. The VCCI method is used with the multi-scale FEM in a delamination risk assessment of a low-k integrated circuits device in flip-chip plastic ball grid array packages. The ERR is calculated for different package configurations and the prediction of the delamination risk is confirmed by reliability tests.     

An enriched element‐failure method (REFM) for delamination analysis of composite structures

This paper develops an enriched element‐failure method for delamination analysis of composite structures. This method combines discontinuous enrichments in the extended finite element method and element‐failure concepts in the element‐failure method within the finite element framework. An improved discontinuous enrichment function is presented to effectively model the kinked discontinuities; and, based on fracture mechanics, a general near‐tip enrichment function is also derived from the asymptotic displacement fields to represent the discontinuity and local stress intensification around the crack‐tip. The delamination is treated as a crack problem that is represented by the discontinuous enrichment functions and then the enrichments are transformed to external nodal forces applied to nodes around the crack. The crack and its propagation are modeled by the ‘failed elements’ that are applied to the external nodal forces. Delamination and crack kinking problems can be solved simultaneously without remeshing the model or re‐assembling the stiffness matrix with this method. Examples are used to demonstrate the application of the proposed method to delamination analysis. The validity of the proposed method is verified and the simulation results show that both interlaminar delamination and crack kinking (intralaminar crack) occur in the cross‐ply laminated plate, which is observed in the experiment. Copyright © 2009 John Wiley & Sons, Ltd.     

Modelling of laminates using a layerwise element with enhanced strains

A layerwise finite element with enhanced strains is developed for the analysis of laminates with special emphasis on determination of interlaminar forces and study of delaminations. An interface model using the penalty function method is developed to calculate strain energy release rates. Since the interface model provides the facility for the closure of delamination by a small amount, strain energy release rates were evaluated by actual crack closure and by virtual crack closure methods for a comparative study. Numerical examples of delamination are presented to illustrate the accuracy of the computational approaches developed herein. © 1998 John Wiley & Sons, Ltd.     

The effect of facesheet/core delamination in sandwich structures under transverse loading

The present work is concerned with the problem of a delamination crack along the facesheet/core interface of a sandwich structure which is submitted to transverse loading. In contrast to a loading by compressive inplane forces or a bending loading the presumed transverse loading does not lead to buckling of the delaminated facesheet but it may provoke further delamination crack growth. As a kind of crack driving force the energy release rate is studied for a virtual crack growth by means of Irwin's crack closure integral within a finite element modelling. The resultant energy release rate is dependent on various geometrical and material parameters which is investigated in some detail.     

Delamination in elastic shear deformable circular layers

This work extends the analytical solution of an interface crack in straight layered structures to circular layered structures. A small segment at the vicinity of an interface crack tip in a circular laminated beam is analyzed by a novel shear deformable bi-layered circular beam theory. Two concentrated forces are found existing at the crack tip due to the requirement of the equilibrium condition. Closed-form solution of the total energy release rate of the interface crack is obtained as the half of the product of the concentrated forces and the corresponding displacement gradient discontinuities at the crack tip. Closed-form expressions of the mode I and II components of the energy release rate are also obtained by global and local methods. Numerical verifications are conducted by analyzing the interlaminar delamination of a circular beam with an edged crack and comparing with the baseline results obtained through finite element analysis. Excellent agreements between the present method and finite element analysis on the predictions of total energy release rate and mode partition verify the accuracy and efficiency of the present solution.     

Cohesive zone with continuum damage properties for simulation of delamination development in fibre composites and failure of adhesive joints

A new approach is developed to implement the cohesive zone concept for the simulation of delamination in fibre composites or crack growth in adhesive joints in tension or shear mode of fracture. The model adopts a bilinear damage evolution law, and uses critical energy release rate as the energy required for generating fully damaged unit area. Multi-axial-stress criterion is used to govern the damage initiation so that the model is able to show the hydrostatic stress effect on the damage development. The damage material model is implemented in a finite element model consisting of continuum solid elements to mimic the damage development. The validity of the model was firstly examined by simulating delamination growth in pre-cracked coupon specimens of fibre composites: the double-cantilever beam test, the end-notched flexure test and the end-loaded split test, with either stable or unstable crack growth. The model was then used to simulate damage initiation in a composite specimen for delamination without a starting defect (or a pre-crack). The results were compared with those from the same finite element model (FEM) but based on a traditional damage initiation criterion and those from the experimental studies, for the physical locations of the delamination initiation and the final crack size developed. The paper also presents a parametric study that investigates the influence of material strength on the damage initiation for delamination.     

In-situ characterization of interface delamination by a new miniature mixed mode bending setup

A new miniature mixed mode bending (MMMB) setup for in-situ characterization of interface delamination in miniature multi-layer structures was designed and realized. This setup consists of a novel test configuration to accomplish the full range of mode mixities and was specially designed with sufficiently small dimensions to fit in the chamber of a scanning electron microscope (SEM) or under an optical microscope for detailed real-time fracture analysis during delamination. Special care was taken to minimize the effects of friction, the influence of gravity, and non-linearities due to the geometry of the setup. The performance of the setup was assessed using specially-designed test samples supported by finite element analyses. Delamination experiments conducted on homogeneous bilayer samples in mode I and mixed mode loading were visualized with a scanning electron microscope and showed the formation of small micro cracks ahead of the crack tip followed by crack bridging and a full crack, thereby demonstrating the advantages of in-situ testing to reveal the microscopic delamination mechanism.     

轮胎结构中层间裂纹扩展过程的数值模拟

轮胎是一个十分复杂的橡胶基复合材料结构,在使用过程中常常发生层间脱层破坏。提出了一种新的复合材料结构中层间脱层裂纹扩展模型,并利用Irwin的虚拟裂纹闭合技术和有限元分析技术对轮胎结构带束层中的层间脱层裂纹扩展过程进行了数值模拟。结果表明,提出的模型能够比较真实地揭示复杂复合材料结构层间脱层裂纹扩展复杂性的特点。     

Prediction of initiation and growth of single level delaminations in a transversely loaded composite specimen using fracture mechanics

The behaviour of a composite test specimen with an embedded delamination subjected to transverse tension has been investigated through experimental testing and finite element (FE) analyses. The testing program consisted of specimens in two geometrical configurations; square and rectangular delamination. The initiation and growth of the delamination was numerically predicted by fracture mechanics. FE models were analysed with both MSC.Nastran and Abaqus FE codes. The MSC.Nastran model was used to calculate strain energy release rates employing a crack tip element methodology. The Abaqus model was evaluated using the virtual crack closure technique. Both approaches accurately predicted failure initiation locations as observed in the test specimens. Failure loads were also well predicted. The mode mix at the crack tip in the proposed specimen was found to be similar to the mode mix expected in a conventional in-plane compression specimen.     

Delamination vs matrix cracking in layered composites subjected to transverse loading

An algorithm is presented to compute the distribution of the strain energy release rate along the crack front of a penny-shaped delamination in a layered orthotropic body. The method applies a finite element recently proposed for three-dimensional analysis of layered orthotropic circular plates. The algorithm is economical even though it treats a full three-dimensional state of stress. The method requires only a single virtual crack extension to accurately compute the strain energy release rate at a point along the crack front. The method is applied to the study of delamination crack growth in a nine layer cross-ply laminate. The variation of strain energy release rate, G, along the crack front, is determined. The significance of the plate aspect ratio, as well as length scale, on the fracture process is studied. The establishment of a loading case where a distributed transverse compressive loading causes delamination growth is given.     

Creep crack initiation at a free edge of an interface between submicron thick elements

To clarify the mechanics of time-dependent crack initiation at an interface edge in submicron thick elements due to creep, delamination experiments are conducted using a micro-cantilever bend specimen with a tin/silicon interface edge. After the specimen time-dependently deforms under a constant load, a delamination crack is initiated at the Sn/Si interface edge. In addition, the steady state creep property of Sn is estimated by performing an inverse analysis using a finite element method based on creep deformation experiments conducted for different specimens. Stress analysis using the obtained creep property reveals that stress and strain rate singularities exist at the Sn/Si interface edge under creep deformation. The intensity of the singular field time-dependently increases as the creep region expands, and eventually it becomes a steady state. The stress and strain rate intensities at the steady state correlate well with the crack initiation life, which indicates that the singular stress field near the interface edge governs the creep crack initiation.     

Stress intensity factors in two bonded elastic layers containing cracks perpendicular to and on the interface—I. Analysis

In this paper the basic crack problem which is essential for the study of subcritical crack propagation and fracture of layered structural materials is considered. Because of the apparent analytical difficulties, the problem is idealized as one of plane strain or plane stress. An additional simplifying assumption is made by restricting the formulation of the problem to crack geometries and loading conditions which have a plane of symmetry perpendicular to the interface. The general problem is formulated in terms of a coupled system of four integral equations. For each relevant crack configuration of practical interest the singular behavior of the solution near and at the ends and points of intersection of the cracks is investigated and the related characteristic equations are obtained. The edge crack terminating at and crossing the interface, the T-shaped crack consisting of a broken layer and a delamination crack, the cross-shaped crack which consists of delamination crack intersecting a crack which is perpendicular to the interface and a delamination crack initiating from a stress-free boundary of the bonded layers are some of the practical crack geometries considered as examples. The formulation of the problem is given in Part I of the paper. Part II deals with the solution of the integral equations and presentation of the results.     

Progressive delamination growth analysis using discontinuous layered element

In this paper, a fracture mechanic approach is used to analyze delamination propagation between layers of composite laminates. A finite element method based on layer-wise theory is extended for the analysis of delamination growth. In this approach, delamination is modeled by jump discontinuity conditions at the interfaces. The layer-wise finite element is developed to calculate the strain energy release rates based on the virtual crack closure technique (VCCT). A procedure is proposed to handle the progressive delamination of laminates. Finally, analyses of the edge delamination propagation for several composite laminates are performed and the corresponding failure stresses are calculated. The predicted results are compared with the available experimental and numerical results. It is shown that the predicted failure stresses using this method are comparable with those obtained using interface elements.