A RAPID METHOD FOR RELIABILITY ANALYSIS OF COMPOSITE TOPHAT STIFFENED STRUCTURES USING A FIRST PRINCIPLES METHOD AND DESIGN RULES

Composite materials are increasingly being used within engineering, especially in low weight applications. A significant drawback that these materials exhibit is their variability. There is a growing trend towards stochastic analysis of marine structures and this is even more important for scenarios that have a high variability. To implement these new techniques it is important to be able to, rapidly and accurately, determine reliability during the design phase. Therefore, a reliability analysis, utilising a rapid implementation, has been performed on plates that have been designed using two different sets of design rules and a first principles method. The results show that whilst, under the limits investigated, the reliability of the design rules are slightly safer than those found using first principles; the sensitivity analysis shows that each of the design rules generates a different reaction from each variable, encouraging different types of structures through their idiosyncrasies. Furthermore the method shown allows a rapid analysis to be performed on complex composite structures in a relatively short time frame using either first principles methods or design rules.

BUCKLING AND POST-BUCKLING OF ISOTROPIC AND COMPOSITE STIFFENED PANELS: A REVIEW ON ANALYSIS AND EXPERIMENT (2000-2012)

Stiffened panels made out of isotropic or anisotropic materials are being extensively used as structural elements for aircraft, maritime, and other structures. In order to maintain stiffness and strength with light weight, new design techniques must be employed when utilising these materials. Their stability, ultimate strength and loading capacity are the key issues pertaining to these engineering structures which have attracted a number of investigators to undertake in- depth research, either in an academic or actual engineering context. This paper provides an extensive review of the research which has been conducted in recent years (2000-2012) on the buckling and post-buckling response of isotropic and composite stiffened plate and shell structures related to analysis and experiment. The key objective of this review article is to collate the research performed in the area of buckling and post-buckling behaviour of stiffened structures, thereby giving a broad perspective of the state-of-the-art in this field.

Effect of forming process on mechanical and interfacial properties for thermoplastic composite I-stiffened structures

The forming process is the core factor to control the quality of thermoplastic composite components. In this paper, the common I-stiffened structures in the aerospace field were taken as the research object, and the forming process scheme was designed. Based on the prefabrication of C-shaped parts, the I-stiffened structures were prepared by the compression molding process. The influence law of molding temperature on the quality of the prefabricated C-shaped parts was explored. The time dependence of the PEEK melt viscosity was tested to provide the basis for the optimization of forming process parameters of I-stiffened structures. The influencing mechanism of thermoplastic composites repeatedly forming to the bonding strength of remelting interface was studied. The results show that repeated forming would lead to polymer aging and result in low bonding strength at the remelting interface of the I-stiffened structures. Optimizing the forming process could effectively reduce the aging of materials and improve the bonding strength of the remelting interface and overall mechanical properties of components. The research provides technical guidance for the manufacturing of complex thermoplastic composite components, especially the influence mechanism of the forming process on the bonding strength of remelting interface.

Optimized Unidirectional and Bidirectional Stiffened Objects for Minimum Material Consumption of 3D Printing

3D printing, regarded as the most popular additive manufacturing technology, is finding many applications in various industrial sectors. Along with the increasing number of its industrial applications, reducing its material consumption and increasing the strength of 3D printed objects have become an important topic. In this paper, we introduce unidirectionally and bidirectionally stiffened structures into 3D printing to increase the strength and stiffness of 3D printed objects and reduce their material consumption. To maximize the advantages of such stiffened structures, we investigated finite element analysis, especially for general cases of stiffeners in arbitrary positions and directions, and performed optimization design to minimize the total volume of stiffened structures. Many examples are presented to demonstrate the effectiveness of the proposed finite element analysis and optimization design as well as significant reductions in the material costs and stresses in 3D printed objects stiffened with unidirectional and bidirectional stiffeners.

Effects of FSW Tool Plunge Depth on Properties of an Al-Mg-Si Alloy T-Joint: Thermomechanical Modeling and Experimental Evaluation

One of the main challenging issues in friction stir welding (FSW) of stiffened structures is maximizing skin and flange mixing. Among the various parameters in FSW that can affect the quality of mixing between skin and flange is tool plunge depth (TPD). In this research, the effects of TPD during FSW of an Al-Mg-Si alloy T-joint are investigated. The computational fluid dynamics (CFD) method can help understand TPD effects on FSW of the T-joint structure. For this reason, the CFD method is employed in the simulation of heat generation, heat distribution, material flow, and defect formation during welding processes at various TPD. CFD is a powerful method that can simulate phenomena during the mixing of flange and skin that are hard to assess experimentally. For the evaluation of FSW joints, macrostructure visualization is carried out. Simulation results showed that at higher TPD, more frictional heat is generated and causes the formation of a bigger stir zone. The temperature distribution is antisymmetric to the welding line, and the concentration of heat on the advancing side (AS) is more than the retreating side (RS). Simulation results from viscosity changes and material velocity study on the stir zone indicated that the possibility of the formation of a tunnel defect on the skin–flange interface at the RS is very high. Material flow and defect formation are very sensitive to TPD. Low TPD creates internal defects with incomplete mixing of skin and flange, and high TPD forms surface flash. Higher TPD increases frictional heat and axial force that diminish the mixing of skin and flange in this joint. The optimum TPD was selected due to the best materials flow and final mechanical properties of joints.

Strain-based health indicators for the structural health monitoring of stiffened composite panels

A common defect of composite-stiffened structures is the disbond at the interface between the two constituents (skin/stringer), as a result of inefficient manufacturing process or foreign object impacts in service. Generally, discontinuities within the volume of an elastic solid medium, subjected to mechanical load, cause anomalies on the strain field in the near vicinity of the discontinuity. Utilizing this observation, this work investigates the effect of artificially induced disbonds in the skin/stiffener interface of an aeronautical-grade generic element. A structural health monitoring methodology is developed, leveraging on numerically simulated strains along the stringer foot which aims to assess the health state of the panel as the size of the disbonds increases. The study is implemented using a parametric finite element model generating various disbond scenarios. Longitudinal strain values are acquired at the exact points where in reality actual fiber Bragg grating sensors will be located. Two types of commonly utilized strain-based health indicators are evaluated, and their drawbacks are revealed and discussed. A new health indicator is proposed that proves its capability to monitor growing disbonds while being both load- and baseline-independent.