On-site monitoring of bearing failure in composite bolted joints using built-in eddy current sensing film

Bearing damage is one of the common failure modes in composite bolted joints. This paper describes the development of an on-site monitoring method based on eddy current (EC) sensing film to monitor the bearing damage in carbon fiber reinforced plastic (CFRP) single-lap bolted joints under tensile testing. Configuration design and operating principles of EC array sensing film are demonstrated. A series of numerical simulations are conducted to analyze the variation of EC when the bearing failure occurs around the bolt hole. The results of damage detection in the horizontal direction and through the thickness direction in the bolt hole with different exciting current directions are presented by the finite element method (FEM). Experiments are performed to prove the feasibility of the proposed EC array sensing film when the bearing failure occurs in CFRP single-lap bolted joints. The results of numerical simulations and experiments indicate that bearing failure can be detected according to the variation of EC in the test specimen.

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On-Site Health Monitoring of Composite Bolted Joint Using Built-In Distributed Eddy Current Sensor Network

Materials ◽

10.3390/ma12172785 ◽

2019 ◽

Vol 12 (17) ◽

pp. 2785 ◽

Cited By ~ 5

Author(s):

Qijian Liu ◽

Hu Sun ◽

Tao Wang ◽

Xinlin Qing

Keyword(s):

Numerical Simulation ◽

Sensor Network ◽

Eddy Current ◽

Failure Modes ◽

Unidirectional Composite ◽

Bolted Joints ◽

Induced Voltage ◽

Hole Edge ◽

Exciting Coil ◽

Array Sensing

There is an urgent need to monitor the structural state of composite bolted joints while still remaining in service; however, there are many difficulties in analyzing their strength and failure modes. In this paper, a built-in distributed eddy current (EC) sensor network based on EC array sensing film is developed to monitor the hole-edge damages of composite bolted joints. The EC array sensing film is bonded onto the bolt and consists of one exciting coil and four separate sensing coils. Experiments are conducted on unidirectional composite specimens to validate the ability of the EC array sensing film to quantitatively track the damage that occurs at the hole edge and to investigate the performances of the EC array sensing films with different configurations of the exciting coil. Experimental results show that the induced voltage of sensing coil changes only if the damage appears on the laminate structure where that particular sensing coil is located, whereas the induced voltages of the other sensing coils on other laminate plates remain unchanged. Numerical simulation based on the finite element method is also carried out to investigate and explain the phenomena observed in the experiments and to analyze the distribution of the EC around the bolt hole. Both experimental and numerical simulation results demonstrate that the developed EC array sensing film can effectively identify not only whether there is damage at the hole edge but also the damage location within the thickness and quantitative size.

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Strength predictions of single-lap woven fabric Kenaf composites bolted joints

JOURNAL OF MECHANICAL ENGINEERING AND SCIENCES ◽

10.15282/jmes.14.4.2020.07.0581 ◽

2020 ◽

Vol 14 (4) ◽

pp. 7389-7395

Author(s):

H. Ahmad ◽

K. Supar

Keyword(s):

Failure Modes ◽

Bolted Joints ◽

Woven Fabric ◽

Strength Prediction ◽

Good Prediction ◽

Bearing Failure ◽

Concentration Problem ◽

Fabric Strength ◽

Kenaf Composites ◽

Kenaf Fibers

Application of woven fabric kenaf fibers in production of polymeric composites (known as woven fabric kenaf reinforced composite (WKRP)) were readily available in the literatures due to excellent tensile strength and elongation at break. Nevertheless, there are less reported work and information regarding to performance of these materials in bolted joints problem. Bolted joints demonstrate complicated damage morphologies either net-tension, shear-out or bearing failure modes dependence upon combination arrays of lay-up/joint variables. XFEM approach has been reported in the literature, yet the agreements are limited to net-tension failure resulting from stress concentration problem. The aim of this paper to carry out strength prediction work of single-lap WKRP/aluminium bolted joints by using Hashin formulation within 3D finite element framework. Hashin formulation which based on ply-by-ply basis seen to perform better prediction to bearing failure modes. The material properties incorporated within Hashin formulation was taken from a single-ply of woven fabric. Strength prediction from Hashin formulation showed a difference of less than ±25% in net tension-bearing failure mode, but less good predictions (some lay-up showed discrepancies of 50%) in smaller W/d to give net-tension mode. Good prediction in net-tension-bearing failure were exhibited in Hashin formulation than XFEM approach as bearing failure is based on ply-by-ply basis due to fiber kinking and matrix compression.

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A novel eddy current array sensing film for quantitatively monitoring hole-edge crack growth in bolted joints

Smart Materials and Structures ◽

10.1088/1361-665x/aae54e ◽

2018 ◽

Vol 28 (1) ◽

pp. 015018 ◽

Cited By ~ 14

Author(s):

Hu Sun ◽

Tao Wang ◽

Qijian Liu ◽

Xinlin Qing

Keyword(s):

Crack Growth ◽

Eddy Current ◽

Edge Crack ◽

Bolted Joints ◽

Hole Edge ◽

Array Sensing

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Temperature effects on joint strength and failure modes of hybrid aluminum–composite countersunk bolted joints

Proceedings of the Institution of Mechanical Engineers Part L Journal of Materials Design and Applications ◽

10.1177/1464420719837299 ◽

2019 ◽

Vol 233 (11) ◽

pp. 2204-2218 ◽

Cited By ~ 2

Author(s):

Calin-Dumitru Coman ◽

Dan Mihai Constantinescu

Keyword(s):

Temperature Effects ◽

Failure Modes ◽

Testing Machine ◽

Material Model ◽

Bolted Joints ◽

Progressive Damage ◽

Damage Analysis ◽

Bearing Failure ◽

Aluminum Composite ◽

Damage Initiation

This paper presents the effects of temperature on the damage initiation and growth in the carbon fiber-reinforced polymer composite laminate of a hybrid aluminum–composite countersunk bolted joints designed for the bearing failure mode. Strain gage measurements conducted using an Instron testing machine coupled to a temperature-controlled chamber together with a detailed three-dimensional finite element model incorporating geometric, material and friction-based full contact nonlinearities are used to investigate the temperature effects on the progressive damage analysis of the orthotropic material model. The progressive damage analysis material model integrates the lamina nonlinear shear deformation, Hashin-type failure criteria and strain-based continuum degradation rules, being developed using the UMAT user subroutine in the MSC Patran-Nastran (MSC Software Corporation) commercial software. The results showed that the temperature effects on damage initiation and failure modes are quite accurately predicted by the progressive damage analysis material model, which proved to be computationally efficient and therefore can predict failure propagation and damage mechanisms. A low temperature increases the limit and ultimate forces and produces net-section failure, while a high temperature favors a bearing failure and even shear-out of the composite adherend of the hybrid aluminum–composite countersunk bolted joint.

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Strength Prediction of Double-Lap Bolted Joints of Woven Fabric CFRP Composite Plates Using Hashin Formulations

Applied Mechanics and Materials ◽

10.4028/www.scientific.net/amm.802.290 ◽

2015 ◽

Vol 802 ◽

pp. 290-294

Author(s):

Hilton Ahmad ◽

Mustafa Abbas Abed

Keyword(s):

Failure Modes ◽

Composite Plates ◽

Bolted Joints ◽

Woven Fabric ◽

Strength Prediction ◽

Bearing Failure ◽

Bolted Joint ◽

Element Analysis ◽

Bearing Failures ◽

Cfrp Composite

Failure modes in composite plates with bolted joint configuration include net-tension, shear-out and bearing failures. Few analytical and numerical approaches in strength prediction frameworks of composite plates with bolted joints were reported in the literatures. Present works are dealing with strength prediction in bearing failure of woven fabric CFRP plates with double lap bolted joint configurations by modeling 3D finite element analysis framework. The pre-processing stage is modeled using commercial ABAQUS CAE package and takes into account all parts interactions, clamping pressure and friction contact. Testing series are following the experimental works found from the literatures with variation of plate width to hole diameter (W/d) ratios and incorporated with finger-tight clamp-up. Hashin failure criterion was implemented as constitutive modeling in current analysis, based on ply-by-ply approaches found to be more appropriate phenomenon in bearing failure. The strength prediction results demonstrated good agreement with all experimental datasets particularly with bearing failures as compared with previously reported work, used stress concentration approach found to be accurate in net-tension failure only.

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Bearing failure of single-/double-shear composite bolted joints: An explicit finite element modeling

Journal of Reinforced Plastics and Composites ◽

10.1177/0731684418772355 ◽

2018 ◽

Vol 37 (14) ◽

pp. 933-944 ◽

Cited By ~ 2

Author(s):

Fangzhou Lu ◽

Deng’an Cai ◽

Ju Tang ◽

Wenlong Li ◽

Jian Deng ◽

...

Keyword(s):

Finite Element ◽

Composite Laminates ◽

Failure Modes ◽

Three Dimensional ◽

Bolted Joints ◽

Bearing Failure ◽

Fiber Failure ◽

Explicit Finite Element ◽

Double Shear ◽

Propagation Law

A three-dimensional explicit finite element method was presented to investigate the bearing failure of single- and double-shear composite bolted joints. To predict the various failure modes of composite laminates, three-dimensional solid elements accompanied by mixed-mode failure criteria considering nonlinear shear behavior were employed in the model. A linear damage propagation law based on the fracture energy and the characteristic length was adopted to alleviate the mesh dependency. In addition, reduced integration elements were used in the models of single- and double-shear joints to avoid the overstiffness. The simulated models were implemented in the Abaqus/Explicit solver with a user-defined material subroutine. The numerical analysis run successfully without any convergence issues. The predictions of mechanical behavior agreed well with the experimental results, with typical damages in the laminates including matrix crack and fiber failure. The effect of secondary bending in the single-shear bolted joint was also analyzed in the explicit modeling.

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