Cohesive Zone Model Modification Techniques According to the Mesh Size in Finite Element Models of Stiffened Panels with Debonding

When catastrophic failure phenomena in aircraft structures, such as debonding, are numerically analyzed during their design process in the frame of “Damage Tolerance” philosophy, extreme requirements in terms of time and computational resources arise. Here, a decrease in these requirements is achieved by developing a numerical model that efficiently treats the debonding phenomena that occur due to the buckling behavior of composite stiffened panels under compressive loads. The Finite Element (FE) models developed in the ANSYS© software (Canonsburg, PA, USA) are calibrated and validated by using published experimental and numerical results of single-stringer compression specimens (SSCS). Different model features, such as the type of the element used (solid and solid shell) and Cohesive Zone Modeling (CZM) parameters are examined for their impact on the efficiency of the model regarding the accuracy versus computational cost. It is proved that a significant reduction in computational time is achieved, and the accuracy is not compromised when the proposed FE model is adopted. The outcome of the present work leads to guidelines for the development of FE models of stiffened panels, accurately predicting the buckling and post-buckling behavior leading to debonding phenomena, with minimized computational and time cost. The methodology is proved to be a tool for the generation of a universal parametric numerical model for the analysis of debonding phenomena of any stiffened panel configuration by modifying the corresponding geometric, material and damage properties.

Core Scale FEM Modeling of Thermochemical Fracturing on Cement Cube Samples

Brownfields and depleting conventional resources of fossil fuel energy are not enough to fulfill the tremendously increasing energy demands around the globe. Unconventional oil and gas resources are creating a huge impact on the enhancement of the global economy. Tight rocks are usually located in deep and high-strength formations. In this study, numerical simulation results on a new thermochemical fracturing approach is presented. The new fracturing approach was implemented to reduce the breakdown pressure of the unconventional tight formations. The hydraulic fracturing experiments presented in this study were carried out on ultra-tight cement block samples. The permeability of the block samples was less than 0.005mD. Thermochemical fracturing was carried out by a thermochemical fluids that caused a rapid exothermic reaction which resulted in the instantaneous generation of heat and pressure. Different salts of nitrogen such as sodium nitrite and ammonium chloride were used as a thermochemical fluid. The instantaneous generation of the heat and pressure caused the creation of micro-cracks. The fracturing results revealed that the novel thermochemical fracturing was able to reduce the breakdown pressure in ultra-tight cement from 1095 psi to 705 psi. The reference breakdown pressure was recorded from the conventional fracturing technique. A finite element (FEM) analysis was conducted using commercial software ABAQUS. In FEM, two approaches were used to model the thermochemical fractures namely, cohesive zone modeling (CZM) and concrete damage plasticity models (CDP). The sensitivity analysis of peak pressure and time to reach the peak pressure is also presented in this study. The sensitivity analysis can help in better designing thermochemical fluids that could lead to the maximum generation of micro-cracks and multiple fractures.

MICROMECHANICAL FINITE ELEMENT PREDICTION OF INTERLAMINAR TRACTION-SEPARATION LAWS USING J-INTEGRAL APPROACH

Dynamic impact loading of woven composites leads to mesoscale damage such as interlaminar transverse cracks and intralaminar tow-tow delamination cracks. At the microscale, this damage may be modeled as fracture between [90/90] and [0/90] unidirectional composite laminates. Microscale finite element model (FEM) resolution of dynamic impact at structural length scale is intractable, but mesoscale FEM resolution is possible with current computational resources. However, mesoscale cohesive zone modeling of this damage requires appropriate tractionseparation laws. These laws are predicted in this work with fiber length-scaleresolved FEMs, which include residual stress, experimentally measured, ratedependent, nonlinear matrix behavior, and experimentally measured, computationally validated, rate-dependent fiber-matrix interface properties. The J-integral from elastoplastic fracture mechanics is computed under mode I and mode II loading and differentiated to determine the traction-separation laws.

On the use of a trilinear traction-separation law to represent stitch failure in stitched sandwich composites

Modern aircraft employ the use of lightweight engineering materials such as sandwich composites to increase the flexural rigidity of their structural components. These sandwich composites are limited by their low interfacial strength between the outer facesheets and internal core, which can result in facesheet-core debonding at relatively low out-of-plane loads. In this study, sandwich composites that are reinforced with through-the-thickness stitching are considered. Stitched sandwich composite specimens, fabricated from 110 kg/m3 perforated foam core with cross-ply carbon/epoxy facesheets, were manufactured with different combinations of stitch densities (0.0016–0.01 stitches/mm2) and linear thread densities (400–1200 Denier) of through-the-thickness reinforcement. Single cantilevered beam (SCB) tests were performed to characterize the facesheet-core debonding within the stitched sandwich composites. Unique fracture morphologies were observed that exhibit dependency on stitch processing parameters. A discrete cohesive zone modeling approach is used to simulate the separation of the facesheet from the core. Three-dimensional finite element analysis reveals crack curvature near the stitching. Good agreement between predicted and experimental measurements were obtained.

Development of a Numerical Model to Simulate Laser-Shock Paint Stripping on Aluminum Substrates

An explicit 3D Finite Element (FE) model was developed in the LS-Dyna code to simulate the laser shock paint stripping on aircraft aluminum substrates. The main objective of the model is to explain the physical mechanisms of the laser shock stripping process in terms of shock wave propagation, stress and strain evolution and stripping shape and size and to evaluate the effects of laser and material parameters on the stripping pattern. To simulate the behavior of aluminum, the Johnson–Cook plasticity model and the Gruneisen equation of state were applied. To simulate stripping, the cohesive zone modeling method was applied. The FE model was compared successfully against experiments in terms of back-face velocity profiles. The parameters considered in the study are the aluminum thickness, the epoxy paint thickness, the laser spot diameter, the fracture toughness of the aluminum/epoxy interface and the maximum applied pressure. In all cases, a circular solid or hollow stripping pattern was predicted, which agrees with the experimental findings. All parameters were found to affect the stripping pattern. The numerical results could be used for the design of selective laser shock stripping tests.