Defining relationships between geometry and behavior of bistable composite laminates

Bistability is exhibited by an object when it can be resting in two stable equilibrium states. Certain composite laminates exhibit bistability by having two stable curvatures of opposite sign with the two axes of curvature perpendicular to each other. These laminates can be actuated from one state to the other. The actuation from the original post-cure shape to the second shape is called as ‘snap-through’ and the reverse actuation is called as ‘snap-back’. This phenomenon can be used in applications for morphing structures, energy harvesting, and other applications where there is a conflicting requirement of a structure that is load-carrying, light, and shape-adaptable. MW Hyer first reported this phenomenon in his paper in 1981. He found that thin unsymmetric laminates do not behave according to the predictions of the Classical Lamination Theory (CLT). The CLT is a linear theory and predicts the post-cure shape of thin unsymmetric laminates to be a saddle. MW Hyer developed a non-linear method called the “Extended Classical Lamination Theory” which accurately predicted the laminate to have two cylindrical shapes. Since then, a number of researchers have tried to identify the key parameters affecting the behavior of such laminates. Geometric parameters such as stacking sequence, fibre orientation, cure cycle, boundary conditions, and force of actuation, have all been studied. The objective of this research is to define a relation between the length, width and thickness of square and rectangular laminates required to achieve bistability. Using these relations, a 36 in × 36 in bistable laminate is fabricated with a thickness of 30 CFRP layers. Also, it is proved that a laminate does not lose bistability with an increase in aspect ratio, as long as both sides of the rectangular laminate are above a certain ‘critical length’. A bistable laminate with dimensions of 2 in × 50 in is fabricated. Further, for laminates that are bistable, it is necessary to be able to predict the curvature and force required for actuation. Therefore, a method is developed which allows us to predict the curvature of both stable shapes, as well as the force of actuation of laminates for which the thickness and dimensions are known. Finite Element Analysis is used to carry out the numerical calculations, which are validated by fabricating laminates. The curvature of these laminates is measured using a profilometer and the force of actuation is recorded using a universal test set-up.

A Dimensionless Characteristic Number for Process Selection and Mold Design in Composites Manufacturing: Part II—Applications

The dimensionless “injectability number” was devised to assist composite engineers in the fabrication of continuous fiber composites by Liquid Composite Molding (LCM), i.e., by injecting a liquid polymer resin through a fibrous reinforcement contained in a mold cavity. Part I of this article introduced the injectability number as the integral of the ratio of the injection pressure to the resin viscosity over the cavity filling time and analyzed the theoretical aspects behind this new concept. For a given mold configuration and reinforcement material characteristics, the invariance of the injectability number with regard to process parameters was demonstrated, and an initial verification in unidirectional injection cases was conducted. Part II completes the analysis by evaluating the injectability number in more complex application cases, confirming its invariance properties. The investigation, which was carried out using numerical simulations of different LCM processes and injection strategies, examined the fabrication of various composite parts: a rectangular laminate, a hood for automotive applications, a reservoir box and a fuselage section for the aerospace industry. The results indicate that more efficient injection strategies lead to lower values of the injectability number, thus enabling the use of this dimensionless number as a tool to assess the difficulty to manufacture a given part by LCM as well as to guide process selection and compare different mold configurations.

An Experimental Investigation of Combined Symmetric-Asymmetric Composite Laminates

It has been found that certain asymmetric composite laminates exhibit bistability, where the composite laminate exhibits multiple stable static equilibrium states. If the bistable composite is actuated, it will snap to its secondary equilibrium state and then remain there without further actuation. This study investigates how the amount of symmetry in a combined symmetric asymmetric rectangular laminate under an imposed clamped edge boundary condition affects the bistability and the curvature of the laminate. Laminates with varying amounts of asymmetry were fabricated and then measured using a profilometer to capture the curvatures of the equilibrium shapes. The results showed that up to 20% symmetry can be introduced in the laminate without a substantial loss in snap through curvature, and that up to 83% symmetry can be introduced in the laminate before bistability is lost. Finite element simulations were conducted in Abaqus and showed good correlation with the experimental results.

Preliminary Study of Optimum Piezoelectric Cross-Ply Composites for Energy Harvesting

Energy harvesting devices based on a piezoelectric material attached to asymmetric bistable laminate plates have been shown to exhibit high levels of power extraction over a wide range of frequencies. This paper optimizes for the design of bistable composites combined with piezoelectrics for energy harvesting applications. The electrical energy generated during state-change, or “snap-through,” is maximized through variation in ply thicknesses and rectangular laminate edge lengths. The design is constrained by a bistability constraint and limits on both the magnitude of deflection and the force required for the reversible actuation. Optimum solutions are obtained for differing numbers of plies and the numerical investigation results are discussed.

Nonlinear Deflection Model for Corner-Supported, Thin Laminates Shape-Controlled With Moment Actuators

The shape control of thin, flexible structures has been studied primarily for edge-supported thin-plates. For applications such as electromagnetic wave reflectors, corner-supported configurations may prove more applicable since they allow for greater flexibility and larger achievable deflections when compared to edge-supported geometries under similar actuation conditions. Models of such structures provide insight for effective, realizable designs, enable design optimization, and provide a means of active shape control. Models for small deformations of corner-supported, thin laminates actuated by integrated piezoelectric actuators have been developed. However, membrane deflections expected for nominal actuation exceed those stipulated by linear, small deflection theories. In addition, large deflection models have been developed for membranes; however these models are not formulated for shape control. This paper extends a previously-developed linear model for a corner-supported thin, rectangular laminate to a more general large deflection model for a clamped-corner laminate composed of moment actuators and an array of actuating electrodes. First, a nonlinear model determining the deflected shape of a laminate given a distribution of actuation voltages is derived. Second, a technique is employed to formulate the model as a map between input voltage and deflection alone, making it suitable for shape control. Finally, comparisons of simulated deflections with measured deflections of a fabricated active laminate are investigated.

Controlling Laminate Plate Elastic Behavior

This paper aims to express the relation of a measure of laminate plate stiffness with respect to the fiber orientation of its plies. The inverse of the scalar product of the lateral displacement of the central plane and lateral loading of the plate is the measure of laminate plate stiffness. In the case of a simply supported rectangular laminate plate this measure of stiffness is maximized, and the optimum orientation of its plies is searched.

Wear of metals: A consequence of stable/unstable material response

Wear of metals in dry sliding is dictated by the material response to traction. This is demonstrated by considering the wear of aluminium and titanium alloys. In a regime of stable homogeneous deformation the material approaching the surface from the bulk passes through microprocessing zones of flow, fracture, comminution and compaction to generate a protective tribofilm that retains the interaction in the mild wear regime. If the response leads to microstructural instabilities such as adiabatic shear bands, the near-surface zone consists of stacks of 500nm layers situated parallel to the sliding direction. Microcracks are generated below the surface to propagate normally away from the surface though microvoids situated in the layers, until it reaches a depth of 10-20 μm. A rectangular laminate debris consisting of a 20-40 layer stack is produced. The wear in this mode is severe.