The mechanical properties of natural fibre based honeycomb core materials

This paper investigates the compression properties of square and triangular honeycomb core materials based on co-mingled flax fibre reinforced polypropylene (PP) and polylactide (PLA) polymers. Initial testing focused on investigating the sensitivity of the tensile properties of the composites to variations in processing conditions. Following this, a range of triangular and square honeycomb structures were manufactured using a simple slotting technique. These structures were tested in compression at quasi-static rates of strain and their strength and specific energy absorption characteristics were determined. Finally, a finite element analysis was undertaken to accurately predict the strength, energy-absorbing characteristics, buckling behaviour and failure modes of these natural fibre based core materials.     

Non-linear finite element analysis of inserts in composite sandwich structures

In aeronautics, sandwich structures are widely used for secondary structures like flaps, landing gear doors or commercial equipment. The technologies used to join these kinds of structures are numerous: direct bonding or joining, tapered areas, T-joints, etc. The most common is certainly the use of local reinforcement called an insert. The insert technologies are numerous and this study focuses on high load bearing capacity inserts. They were made with a resin moulded in the Nomex™ sandwich core. Such structures are still designed mainly empirically and the lack of efficient numerical models remains a problem. In this study, pull-out tests were conducted on a representative sample and the non-linearities and the types of failure were analysed. Core shear bucking, failures of the potting and perforation of the composites skins are the main modes of failure. For each mode, local experimental and numerical analysis was carried out that led to the identification of the independent non-linear behaviour of each component. Including the results in a global non-linear finite element model gave good prediction of the failure scenario and an acceptable correlation with the tests.     

An experimental study on the long-term behavior of CFRP pultruded laminates suitable to concrete structures rehabilitation

The rheological behavior of structural materials has a significant role indeed in Civil Engineering, where concrete and FRP (Fiber Reinforced Polymer) materials undergo creep in normal environmental conditions, while steel exhibits a sizable creep only at high temperature (above 400 °C). With reference to RC structures strengthened by means of FRP laminates, FRP creep generally coexists with concrete cracking. The interaction between these phenomena should be taken into account in order to evaluate the structural durability. Here, the first results of a research program on creep in composite pultruded laminates used in Civil Engineering are presented, under various stress levels and in constant environmental conditions (many theoretical and experimental studies on creep have been performed so far in the aerospace and naval fields, but not as many in Civil Engineering). The specimens tested in this project are made of high modulus carbon fiber reinforced polymer – CFRP, whose mechanical properties are tailored for Civil Engineering applications. The tests are still in progress in the Material and Structures Testing Laboratory of the Civil Engineering Department of the University of Salerno (Italy).     

Effects of inter-fibre spacing and matrix cracks on stress amplification factors in carbon-fibre/epoxy matrix composites. Part I: planar array of fibres

When the loading on a composite is sufficient to cause fracture of an individual fibre, the resulting stress amplification in the adjacent intact fibres may be large enough to cause failure of these fibres. In this work, 3D elasto-plastic finite element analysis was used to investigate the effect of inter-fibre spacing on the stress amplification factor in a composite comprising a planar array of fibres. A Progressional Approach was used in the FE analysis to simulate the constituent non-linear processes associated with the generation of thermal residual stresses from fabrication, the fibre fracture event and the subsequent initiation and propagation of conical matrix cracks induced with incremental tensile loading. As the inter-fibre spacing increases, the effect of fibre fracture on the stress distribution in the neighbouring intact fibres is reduced, whereas the effect on the matrix material is increased, thereby inducing localised yielding. The presence of a conical-shaped matrix crack was found to increase both the stress amplification factor and the positively affected length in neighbouring fibres. For a large inter-fibre spacing, a longer matrix crack is required to obtain good agreement with LRS measurements of fibre stress.     

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.     

Progressive damage analysis as a design tool for composite bonded joints

This paper discusses the application of progressive damage analysis (PDA) methods as a design tool. Two case studies are presented in which the effects of changing design features on the strength of bonded composite joints are evaluated. It is shown that the trends of parametric evaluations performed with full-featured PDA models can be unintuitive and the trends can be opposite to those obtained with traditional design criteria. The joint configurations that were tested exhibit multiple damage modes, requiring several different PDA tools to accurately predict the structural peak loads. For damage tolerant structures that exhibit complex sequences of multiple failure mechanisms, traditional failure prediction tools are insufficient. Parametric PDA models encompassing a bonded joint specimen's design space have the potential to reveal unintuitive and advantageous design changes.     

Modelling the forming mechanics of engineering fabrics using a mutually constrained pantographic beam and membrane mesh

A method of combining 1-d and 2-d structural finite elements to capture the fundamental mechanical properties of engineering fabrics subject to finite strains is introduced. A mutually constrained pantographic beam & membrane mesh is presented and simple homogenisation theory is developed to relate the macro-scale properties of the mesh to the properties of the elements within the mesh. The theory shows that each of the macro-scale properties of the mesh can be independently controlled. An investigation into the performance of the technique is conducted using tensile, cantilever bending and uniaxial bias extension shear simulations. The simulations are first used to verify the accuracy of the homogenisation theory and then used to demonstrate the ability of the modelling approach in accurately predicting the shear force, shear kinematics and out-of-plane wrinkling behaviour of engineering fabrics.