Linear-Nonlinear Stiffness Responses of Carbon Fiber-Reinforced Polymer Composite Materials and Structures: A Numerical Study

Mechanistic Study of Failure in CFRP Hybrid Bonded-Bolted Interference Connection Structures under Tensile Loading

Hybrid bonded-bolted composite material interference connections significantly enhance the collaborative load-bearing capabilities of the adhesive layer and bolts, thus improving structural load-carrying capacity and fatigue life. So, these connections offer significant developmental potential and application prospects in aircraft structural assembly. However, interference causes damage to the adhesive layer and composite laminate around the holes, leading to issues with interface damage. In this study, we employed experimental and finite element methods. Initially, different interference-fit sizes were selected for bolt insertion to analyze the damage mechanism of the adhesive layer during interference-fit bolt installation. Subsequently, a finite element tensile model considering damage to the adhesive layer and composite laminate around the holes post-insertion was established. This study aimed to investigate damage in composite bonded-bolted hybrid joints, explore load-carrying rules and failure modes, and reveal the mechanisms of interference effects on structural damage and failure. The research results indicate that the finite element prediction model considering initial damage around the holes is more effective. As the interference-fit size increases, damage to the adhesive layer transitions from surface debonding to local cracking, while damage to the composite matrix shifts from slight compression failure to severe delamination and fiber-bending fracturing. The structural strength shows a trend of initially increasing and then decreasing, with the maximum strength observed at an interference-fit size of 1.1%.

Optimal Roving Winding on Toroidal Parts of Composite Frames

Frames made of polymer composites are increasingly used in the aerospace, automotive, and agricultural industries. A frequently used technology in the production line of composite frames is winding rovings onto a non-load-bearing frame to form the structure using an industrial robot and a winding head, which is solidified through a subsequent heat-treatment pressure process. In this technology, the most difficult procedure is the winding of the curved parts of a composite frame. The primary concern is to ensure the proper winding angles, minimize the gaps and overlaps, and ensure the homogeneity of the wound layers. In practice, the curved frame parts very often geometrically form sections of a torus. In this work, the difficulty of achieving a uniform winding of toroidal parts is described and quantified. It is shown that attaining the required winding quality depends significantly on the geometrical parameters of the torus in question. A mathematical model with a detailed procedure describing how to determine the number of rovings of a given width on toroidal parts is presented. The results of this work are illustrated with practical examples of today's industrial problems.

A Fatigue Model to Predict Interlaminar Damage of FRP Composite Laminates Subjected to Mode I Load

In fiber-reinforced polymer (FRP) composite laminate structures operating under fluctuating stresses, interface delamination is seen as one of the significant damage mechanisms. The constant degradation of their relatively low interlaminar strength and stiffness are the primary reasons for delamination. This study develops an interlaminar fatigue damage model to quantify the mechanics of the damage process and address the reliability of composite structures. The model considers the failure process in two stages: (1) damage due to degradation of interlaminar elastic properties, and (2) damage due to dissipation of fracture energy through the damage evolution process. The model is examined for a case study of mode I fatigue loading of a carbon-fiber-reinforced polymer (CFRP) composite laminate. The results show that the interlaminar normal stress is confined to the crack front region, with tensile stress peaks at 70% of the interlaminar strength. Furthermore, a stable interface crack growth is predicted initially, followed by a sudden crack "jump" at 14,000 cycles. The simulation results are compared with the experimental data, with very good agreement, showing a successful validation of the fatigue model.

Lightweight Glass Fiber-Reinforced Polymer Composite for Automotive Bumper Applications: A Review

The enhancement of fuel economy and the emission of greenhouse gases are the key growing challenges around the globe that drive automobile manufacturers to produce lightweight vehicles. Additionally, the reduction in the weight of the vehicle could contribute to its recyclability and performance (for example crashworthiness and impact resistance). One of the strategies is to develop high-performance lightweight materials by the replacement of conventional materials such as steel and cast iron with lightweight materials. The lightweight composite which is commonly referred to as fiber-reinforced plastics (FRP) composite is one of the lightweight materials to achieve fuel efficiency and the reduction of CO₂ emission. However, the damage of FRP composite under impact loading is one of the critical factors which affects its structural application. The bumper beam plays a key role in bearing sudden impact during a collision. Polymer composite materials have been abundantly used in a variety of applications such as transportation industries. The main thrust of the present paper deals with the use of high-strength glass fibers as the reinforcing member in the polymer composite to develop a car bumper beam. The mechanical performance and manufacturing techniques are discussed. Based on the literature studies, glass fiber-reinforced composite (GRP) provides more promise in the automotive industry compared to conventional materials such as car bumper beams.

Strain-Field Modifications in the Surroundings of Impact Damage of Carbon/Epoxy Laminate

The relationship between deformation and stress is crucial for any elasto-plastic body. This paper deals with the experimental identification of the basic parameters of the composite laminate model in relation to the finite element model. Standardized tensile, impact, and post-impact tests on a carbon fiber-reinforced epoxy laminate were used. The method by which the elasticity and failure parameters were obtained from the initial components is described. In the article, the modes of initiation and complete failure of samples in tensile tests, which are compared with the simulation, are presented. Furthermore, the article deals with the issue of the generation and detection of damage by low-speed impact, which can be caused by contact with moving objects, due to improper handling or maintenance. The results of impact analysis simulations are shown in the context of strain-field distribution changes obtained with the help of digital image correlation. The results showed high agreement between the calculations and the experiments. Based on this agreement, simulations of impact damage for various energies were performed. These simulations were used to determine the approximate sizes of the affected zones in relation to the impact energy. The results are finally discussed in the context of the possible use of structural health monitoring based on strain modifications.

Progressive Damage Behaviour Analysis and Comparison with 2D/3D Hashin Failure Models on Carbon Fibre–Reinforced Aluminium Laminates

It is known that carbon fibre–reinforced aluminium laminate is the third generation of fibre metal materials. This study investigates the response of carbon fibre–reinforced aluminium laminates (CARALL) under tensile loading and three-point bending tests, which evaluate the damage initiation and propagation mechanism. The 2D Hashin and 3D Hashin VUMAT models are used to analyse and compare each composite layer for finite element modelling. A bilinear cohesive contact model is modelled for the interface failure, and the Johnson cook model describes the aluminium layer. The mechanical response and failure analysis of CARALL were evaluated using load versus deflection curves, and the scanning electron microscope was adopted. The results revealed that the failure modes of CARALL were mainly observed in the aluminium layer fracture, fibre pull-out, fracture, and matrix tensile fracture under tensile and flexural loading conditions. The 2D Hashin and 3D Hashin models were similar in predicting tensile properties, flexural properties, mechanical response before peak load points, and final failure modes. It is highlighted that the 3D Hashin model can accurately reveal the failure mechanism and failure propagation mechanism of CARALL.

Linearization of Composite Material Damage Model Results and Its Impact on the Subsequent Stress–Strain Analysis

To solve problems in the field of mechanical engineering efficiently, individual numerical procedures must be developed, and solvers must be adapted. This study applies the results of a carbon-fibre reinforced polymer (CFRP) analysis along with the nonlinear finite element damage (FE) method to the translation of a linear solver. The analyzed tensile test sample is modelled using the ply-by-ply method. To describe the nonlinear post-damage behavior of the material, the Hashin model is used. To validate the transformation, an analysis and comparison of the damage results of the linearized and nonlinear model is carried out. Job linearization was performed by collecting elements into groups based on their level of damage and pairing them with unique material cards. Potentially suitable mathematical functions are tested for the grouping and consolidation of the elements. The results show that the agreement of some presented methods depends on the damage level. The influence of the selected statistical functions on the result is shown here. The optimal solution is demonstrated, and the most efficient method of linearization is presented. The main motivation behind this work is that the problem has not been discussed in the literature and that there is currently no commercial software translator that provides the transference of models between solvers.