Influence of Assembly Parameters on Tensile Behavior of Hybrid CMC and Superalloy Bolted Joints by Progressive Damage Analysis

With the considerable applications of ceramic matrix composites(CMC) in aircraft engineering, the design of CMC bolted joint gains paramount attention because of its capacity to to improve load-bearing efficiency of aircraft key structure. In this work, a 3 D finite element model was established to predict tensile performance and failure modes of single-lap, single-bolt 2 D C/SiC composite, and superalloy joint, which considers the progressive damage behavior of 2 D woven C/SiC composites. On the basis of the developed progressive damage model, a parametric study was carried out to illustrate the effects of bolt preload and bolt-hole clearance on mechanical behaviors of the hybrid bolted joint. It was found that the increase in the value of bolt preload made the failure load grow first and then drop, and the optimum value of bolt preload 5.00 kN generated 56.47% rise in the initial failure load and 22.83% rise in the final failure load for the bolted joint in comparison with zero preload case. As the clearance increased from 0 to 2.00%, the initial and final failure loads respectively declined by 45.88% and 24.02% for 2.00% bolt-hole clearance relative to the neat-fit case. The loss in failure loads can be reduced to compressive stress concentration around the fastening hole-edge area, leading to the appearance of earlier damages by the introduction of increasing bolt hole clearance.

Progressive Analysis of Bearing Failure in Pin-Loaded Composite Laminates Using an Elasto-Plastic Damage Model

Bearing failure of composite laminate is very complicated due to the complexity of different failure mechanisms and their interactions. In this paper, an elasto-plastic damage model is built up to describe the process of failure in composite laminates subjected to bearing load. Non-linear behavior of composite before failure is taken into consideration by using a modified Sun-Chen one parameter plasticity model. LaRC05 failure criteria are employed to predict the initiation of failure and the evolution of failure is described by a CDM based stiffness degradation model. Both theory and some application issues like parameter determination are discussed according to phenomenon of experiments. The model is firstly validated by several experiment results of unidirectional laminate and then applicated into the progressive analysis of bearing failure in pin-loaded multidirectional laminates, both intralaminar and interlaminar damage are taken into consideration. The result of finite element analysis is compared with experiment results;it shows good agreements in both mechanical response and progress of failure, so the model can be evaluated to be effective and practical in bearing failure analysis of composite laminates.

Research on Fatigue Damage Behavior of Main Beam Sub-Structure of Composite Wind Turbine Blade

Given the difficulty in accurately evaluating the fatigue performance of large composite wind turbine blades(referred to as blades),this paper takes the main beam structure of the blade with a rectangular cross-sectionas the simulation object and establishes a composite laminate rectangular beam structure that simultaneouslyincludes the flange,web,and adhesive layer,referred to as the blade main beam sub-structure specimen,throughthe definition of blade sub-structures.This paper examines the progressive damage evolution law of the compositelaminate rectangular beam utilizing an improved 3D Hashin failure criterion,cohesive zone model,B-K failurecriterion,and computer simulation technology.Under static loading,the layup angle of the anti-shear web hasa close relationship with the static load-carrying capacity of the composite laminate rectangular beam;under fatigueloading,the fatigue damage will first occur in the lower flange adhesive area of the whole composite laminaterectangular beam and ultimately result in the fracture failure of the entire structure.These results provide a theoreticalreference and foundation for evaluating and predicting the fatigue performance of the blade main beamstructure and even the full-size blade.

PROGRESSIVE DAMAGE ARREST MECHANISM IN TAILORED LAMINATED PLATES WITH A CUTOUT

This study addresses the effectiveness of a simple stiffness tailoring concept to delay damage initiation, control damage progression, and improve residual strength in tensile-loaded composite plates with a central circular cutout. The tailoring concept is to simply reposit all axially oriented （0°） material into regions near the edge of the plate away from the cutout. This tailoring is done in a way so as not to affect the weight of the plate. This accomplishes several beneficial changes in the way that the plate resists loading with no increases in material cost or weight. Lowering the axial stiffness of the laminate surrounding the cutout lowers the stress concentration. Increasing the axial stiffness near edges of the plate attracts loading away from the vicinity of the cutout to further lower stresses in the critical cutout region. This study focuses on in-plane response including damage progression and residual strength as a function of the degree of tailoring and cutout size. Strength and stiffness properties typical of IM7/8551-7 preperg material were assumed and a modified version of the Hashin failure criteria was used to identify the local damage. Results show that tailoring can significantly increase the damage initiation load and the residual strength. In some cases, observed evidence shows that tailoring performs as a damage arrest mechanism.

Progressive Failure Analysis of Quasi-isotropic Self-reinforced Polyethylene Composites by Comparing Unsupervised and Supervised Classifications of Acoustic Emission Data

Unsupervised and supervised pattern recognition( PR)techniques are used to classify the acoustic emission( AE) data originating from the quasi-isotropic self-reinforced polyethylene composites,in order to identify the various mechanisms in the multiangle-ply thermoplastic composites. Ultra-high molecular weight polyethylene / low density polyethylene( UHMWPE / LDPE)composites were made and tested under quasi-static tensile load. The failure process was monitored by the AE technique. The collected AE signals were classified by unsupervised and supervised PR techniques, respectively. AE signals were clustered with unsupervised PR scheme automatically and mathematically. While in the supervised PR scheme,the labeled AE data from simple lay-up UHMWPE / LDPE laminates were utilized as the reference data.Comparison was drawn according to the analytical results. Fracture surfaces of the UHMWPE / LDPE specimens were observed by a scanning electron microscope( SEM) for some physical support. By combining both classification results with the observation results,correlations were established between the AE signal classes and their originating damage modes. The comparison between the two classifying schemes showed a good agreement in the main damage modes and their failure process. It indicates both PR techniques are powerful for the complicated thermoplastic composites. Supervised PR scheme can lead to a more precise classification in that a suitable reference data set is input.

Bolt Design of Ceramic Matrix Composite and Superalloy Bolted Joint Based on Damage Failure Load

Ceramic matrix composite(CMC)and superalloy bolted joints are commonly used high temperature connection structures in aerospace and aeronautical fields.In this paper,a finite element model coupled with progressive damage analysis of 2D C/SiC composites and superalloy bolted joint was implemented to simulate the uniaxial tensile loading process by using the ABAQUS finite element software.The parametric effects of raised head bolt on stress distribution,tensile performance,and damage process were studied for the CMC⁃superalloy bolted joint structures.The results showed that the final failure load increased first to the maximum value,and then decreased with the rise of bolt diameter,bolt head diameter,and bolt head thickness,respectively.When the three parameters were 5.0 mm,9.5 mm,and 2.8 mm for the current studied bolt configuration,the joint structure gave the maximum load bearing capacity for the considered parameter ranges.It was also found that around 42%potential improvement in load bearing capacity could be achieved by very small adjustments in bolt parameters of the joints.

考虑剪切非线性的复合材料层合板渐进损伤数值模拟

基于连续损伤力学的基本原理,建立了考虑剪切非线性的三维渐进损伤模型,分析预测复合材料层合板的力学行为、失效载荷以及失效机理。选用高阶指数函数描述复合材料的剪切非线性行为,考虑复合材料刚度渐进和突然折减的组合方式来表征损伤过程中材料的刚度变化,编制了UMAT子程序,采用ABAQUS软件对带孔AS4/PEEK复合材料层合板进行渐进损伤失效分析。本文提出的模型与传统不考虑剪切非线性的模型相比,仿真结果精度更高,与已报道试验对比误差值小于4%。模拟结果显示,孔径越大,损伤发生前,圆孔附近的应力极限值越大,应力分布梯度越大,层合板承载能力越小。当采取[±45]_(2S)铺层方式时,仿真应力与试验结果具有很好的一致性,也进一步验证了模型的适用性和准确性。

复合材料格栅结构筋条纤维形态与拉伸性能

复合材料格栅结构已大量应用于航空航天飞行器中,探究其力学性能具有重要的工程研究价值。为提高复合材料格栅结构的承载效率,提出一种基于“断筋”处理的纤维形态改善方法,通过有限元分析与试验验证的手段,研究了不同断筋比例对复合材料格栅结构节点处纤维形态和拉伸性能的影响。利用建立的有限元模型分析了断筋处理的复合材料格栅结构拉伸失效机理,仿真与试验结果误差均小于10%。结果表明:在成型过程中适当进行断筋处理,能够显著降低节点处纤维弯曲角度,提高拉伸性能。相较于不进行断筋处理,断筋比例为30%时,拉伸极限载荷提高了24.4%。

压缩载荷下非对称变厚度复合材料层合板性能研究

对非对称结构形式的变厚度复合材料层合板在准静态压缩载荷下的失效机理进行了试验和数值研究。在ABAQUS/Explicit中建立全新的三维有限元模型(Finite element model, FEM),其中Hashin准则用于复合材料层合板渐进失效分析,内聚力建模用于模拟分层的萌生和扩展。根据试验得到的应变数据分析,不连续的中性轴使层合板中产生弯矩,这些弯矩与轴向压缩载荷相互耦合,共同作用在层合板上。有限元结果表明,在薄段和变厚度段的交界处存在明显的应力集中,且薄段的应力大于厚段的应力。在交界处,发生了分层以及纤维和基体的压缩损伤,这与试验的结果一致。FEM预测的极限荷载比试验测得的平均极限荷载小10.7%,证明了模型的可行性和合理性。

碳纤维复合材料车门防撞梁多尺度高效变形模拟及实验验证

以碳纤维复合材料车门防撞梁为例,开发了一种面向工程零部件的多尺度高效变形模拟技术,建立了自洽聚类分析方法及多尺度渐进损伤本构模型,通过多尺度单元与唯象单元混合建模,有效降低了模型的求解成本,通过将有限的计算资源分配在恰当的位置,结果表明计算资源的利用效率得到显著提升,实现了工程零部件损伤行为的高效预测,实际计算时间缩短至原来的1/4。对三点弯状态下复合材料防撞梁的宏微观渐进损伤过程进行了分析。基于真空袋成形工艺进行了防撞梁样件试制以及三点弯破坏实验,验证了仿真结果的准确性。

复材风扇叶片榫头元件低周疲劳和损伤模式

为考核层合结构复材风扇叶片在1.5倍离心载荷下的低周疲劳寿命,制备一批风扇叶片,在薄弱部位取样。通过建立层合结构风扇叶片有限元模型,模拟榫头的应力状态,从而确定拉伸载荷水平,开展拉-拉载荷低周疲劳测试。在相邻铺层间引入内聚力单元,并考虑榫头试样单向带面内损伤,模拟损伤变量随循环数累积的过程,增加虚拟拉伸载荷,得到榫头低周疲劳失效时刻的损伤状态。试验结果说明榫头元件形成分层裂纹的平均寿命为17207次循环,首次出现分层裂纹的位置基本一致。数值仿真结果表明榫头单向带基体和层间损伤累积引起裂纹扩展,导致低周疲劳失效。本研究可为建立层合结构复材风扇叶片低周疲劳寿命试验流程和疲劳失效判据提供支撑。

考虑边坡渐进破坏特性的新型条分法及其应用

为了分析边坡的渐进破坏过程,以剩余推力法为例,应用剪应力—应变本构模型对传统条分法进行改进。分析了新型条分法的基本原理,提出基于临界状态的滑坡稳定性评价系数。根据稳定系数的变化可以判断滑坡不同阶段的滑体稳定情况。应用新型条分法对西北地区的一个滑坡进行稳定分析,并将分析结果与监测位移对比,证明了新条分法的可行性。

玻璃纤维平纹编织层合板面内剪切渐进失效分析

为研究玻璃纤维平纹编织层合板面内剪切性能,建立其面内剪切渐进失效分析模型。基于Ramberg-Osgood方程建立考虑面内剪切的非线性本构模型,编写VUMAT子程序,设置Hashin失效准则和刚度退化准则,采用ABAQUS/Explicit求解器对玻璃纤维平纹编织层合板的面内剪切过程进行模拟。研究表明:建立的非线性模型能够很好地描述面内剪切非线性;面内剪切过程中,首先发生纤维-基体的剪切失效,然后是经纬向纤维的拉伸失效,最后是经纬向纤维的压缩失效;预测得到的面内剪切强度、初始剪切模量、位移载荷曲线和失效模式与试验结果吻合,证明所建立模型的有效性。

复合材料径向和轴向螺栓连接失效预测方法及失效模式分析

大型火箭舱段间的复合材料端框连接主要由径向螺栓连接和轴向螺栓连接组成,设计了不同铺层和几何尺寸的连接试验件,并通过试验获得了失效载荷和失效形式。然后,选择了3种渐进损伤方法进行了连接结构的失效预测,并将预测结果与试验结果进行比较,结果表明:采用基于细观力学的复合材料渐进损伤方法,15组径向连接试验件失效载荷计算误差最大为17.3%;4组轴向连接失效载荷计算误差最大7.4%;预测的失效形式与试验结果接近,为连接结构确定了合适的失效预测方法。采用数值分析结果揭示了复合材料单向层的主要失效模式。为复合材料端框连接的设计研究提供了可用的失效预测方法及详细的失效模式分析结果。

干法/湿法挖补修理层合板力学性能的对比研究

挖补修理是一种常用的受损复合材料结构修复方法,主要可分为干法(预固化补片)修理和湿法(湿铺贴)修理。通过开展静力拉伸实验,研究了不同损伤尺寸的预固化补片挖补修理和湿铺贴挖补修理层合板的极限强度、破坏模式以及补片脱粘情况,实验结果表明采用预固化补片修理的结构其强度恢复率更高,补片提前脱粘概率更低,修理效果更好。在力学实验的基础上,通过有限元计算准确预测了挖补修理层合板的极限强度、应力应变分布和损伤演化过程,计算结果表明预固化补片修理结构的胶层应力分布更加均匀,应力水平和应力集中程度更低,出现界面失效和胶层内聚失效的载荷也更高。

基于FEA的复合材料结构极限承载失效预测

针对复合材料层合板失效分析,基于经典层合板理论与一阶剪切变形理论,通过层合板等效刚度以及各单层板的应力应变建立了一种并行多尺度方法,并基于此方法采用FORTRAN语言编写了子程序,通过与试验结果以及有限元分析(Finite Element Analysis,FEA)软件内嵌的复合材料失效模型进行对比,证实了并行多尺度方法的可行性,实现了对复合材料层合板在多种工况情况下的渐进损伤分析。

碳-玻混杂复合材料单钉单剪螺栓连接结构失效模式及渐进损伤分析

采用试验和数值模拟相结合的方法,研究碳-玻混杂复合材料螺栓连接结构的失效载荷、失效模式及其渐进损伤过程。基于ABAQUS平台建立了36种不同宽径比(W/D)、端径比(E/D)连接结构的有限元模型。根据三维Hashin失效准则和三维Chang-Chang失效准则,结合连接结构的拉伸试验,分析了结构尺寸E/D、W/D对失效载荷和失效模式的影响,探讨了不同失效模式下的渐进损伤过程。研究结果表明,一定混杂比的碳-玻复合材料螺栓连接结构的失效主要有挤压失效、剪切-挤压混合失效、拉伸失效三种模式;连接结构的结构尺寸E/D、W/D对结构的失效载荷和失效模式影响较大;连接结构的挤压失效模式是层合板在螺栓孔挤压边轴线位置发生基体挤压损伤,并沿轴线方向呈扇形向外扩展至结构失效;剪切-挤压破坏模式是层合板在螺栓孔至端面处发生大量纤维和基体的拉伸损伤,伴随螺栓孔受压边基体挤压损伤,形成豁口至结构失效;拉伸失效模式是层合板在螺栓孔上下位置发生纤维和基体拉伸损伤,并沿横向扩展至层合板上下边缘至结构失效。

基于主成分回归法的Johnson-Cook损伤准则的渐进成形破裂预测

板材加工过程中时常会产生裂痕甚至破裂,为了能够更加精确地预测出板料成形时破裂的高度,以Johnson-Cook损伤准则为标准,采用主成分分析法,通过正交实验的方法测量破裂数据,使用SPSS和MALTAB数据分析软件具体诠释了刀具直径、层间距、成形角、板料厚度、成形高度和制件尺寸这6个工艺参数对破裂的影响,构建出渐进成形板材破裂预测线性回归方程。结果表明:基于16个工作件的实测数据建立的主成分回归模型,预测得出两试验件板材破裂高度分别为−10.7530 mm和−10.8150 mm,与实际破裂高度误差仅为3.84%和6.14%。由此可见,板材破裂模型具有一定的可行性和准确性,可以更好地预测板料破裂高度,尽可能地防止成形缺陷。

基于HFGMC理论的复合材料协同多尺度损伤模拟

为进行复合材料协同多尺度渐进损伤的分析,提出一种基于高保真通用胞元法和有限元相结合的方法。推导高保真通用胞元的计算格式,并通过一个典型周期性单胞的分析结果与有限元结果的对比,验证所建模型的精确性。采用所建立的方法对一个单向复合材料缺口试验件的渐进损伤过程进行协同多尺度模拟,揭示试验件宏观性能衰减与微观尺度损伤演化之间的内在联系。结果说明:该方法适用于复合材料多尺度分析。

基于CDM的复合材料层合板三维非线性渐进损伤分析

建立了基于连续介质损伤力学(CDM)的中等尺度复合材料层合板三维渐进损伤分析模型。模型中损伤材料本构方程采用对应于不同损伤模式的内部状态变量进行描述,材料失效准则采用三维HASHIN准则。分析了含孔复合材料层合板压缩试件,计算强度与试验数据的吻合表明该模型可用于预测含孔层合板的压缩强度,同时该模型可以预测层合板的失效模式以及损伤发生、扩展直至最终破坏的整个过程,并且该模型具有较好的计算收敛性。