Experimental-Numerical Failure Analysis of Thin-Walled Composite Columns Using Advanced Damage Models

The paper analyzes the stability and failure phenomenon of compressed thin-walled composite columns. Thin-walled columns (top-hat and channel section columns) were made of carbon fiber reinforced polymer (CFRP) composite material (using the autoclave technique). An experimental study on actual structures and numerical calculations on computational models using the finite element method was performed. During the experimental study, post-critical equilibrium paths were registered with acoustic emission signals, in order to register the damage phenomenon. Simultaneously to the experimental tests, numerical simulations were performed using progressive failure analysis (PFA) and cohesive zone model (CZM). A measurable effect of the conducted experimental-numerical research was the analysis of the failure phenomenon, both for the top-hat and channel section columns (including delamination phenomenon). The main objective of this study was to be able to evaluate the delamination phenomenon, with further analysis of this phenomenon. The results of the numerical tests showed a compatibility with experimental tests.     

Design and Preparation of Double-Harmonic Piezoelectric Composite Lamination

In this work, a new type of double-harmonic piezoelectric composite laminated structure is designed. Two bending vibration frequencies are generated by designing the structure with non-equal length and non-equal width, and the response is relatively consistent at the frequency point of the double-harmonic vibration. Firstly, the finite element software ANSYS is used to establish the simulation model of double-harmonic piezoelectric composite lamination. Two bending vibration frequencies are generated by using the non-equal length structure design, and the variation law of the conductance curve with the laminated structure is analyzed. Then, according to this law, the structure is optimized, and a non-equal width structure is further proposed in this work. Different double-harmonic piezoelectric composite laminations are prepared for comparison. The simulation and experimental results show that the value of the corresponding conductance curve at the two vibration frequency points can be increased or reduced by changing the lamination width. Then, the same conductance peak can be obtained to have a relatively consistent response at the double-harmonic frequency point. This will provide a good choice for expanding the transducer bandwidth and developing the broadband energy collector.     

Multiscale Simulation of Composite Structures: Damage Assessment,Mechanical Analysis and Prediction

Composites can be engineered to exhibit high strength, high stiffness, and high toughness. Composite structures have been used increasingly in various engineering applications. In recent decades, most fundamentals of science have expanded their reach by many orders of magnitude. Currently, one of the primary goals of science and technology seems to be the quest to develop reliable methods for linking the physical phenomena that occur over multiple length scales, particularly from a nano-/micro-scale to a macroscale. The aim of this Special Issue is to assemble high quality papers that advance the field of multiscale simulation of composite structures, through the application of any modern computational and/or analytical methods alone or in conjunction with experimental techniques, for damage assessment or mechanical analysis and prediction.     

Experimental Study on Compression Failure of Composite Laminates with Prefabricated Surface Cracks

A new compression test fixture was designed in the present work to study the damage tolerance of composite laminates with surface cracks or notches. The compression failure behaviors of CCF300/5228A quasi-isotropic composite laminates with prefabricated surface cracks were studied experimentally. Through the size design of the test fixture and specimens and an application of a simple test method, the complex crack growth process was captured. The experimental results showed that the compression failure modes were mainly affected by crack angles and depths, and there were two typical failure modes, which were local intra- and inter-laminar damage propagating from the crack tips and delamination growth induced from the crack leading edge. This study verified the validity of the test fixture and test method, and revealed the compression failure mechanisms of composite laminates with surface cracks.     

Structural Analysis of Composite Conical Convex-Concave Plate (CCCP) Using VAM-Based Equivalent Model

Compared with the ordinary foundation plate, the composite conical convex-concave plate (CCCP) has obvious anisotropic characteristics, and there is less research on the relationship between its mechanical properties and structural parameters. In this article, a numerical model for the equivalent stiffness of a typical unit cell with conical convex is established by using the variational asymptotic method. Then, the 3D finite element model (3D-FEM) of CCCP is transformed into 2D equivalent plate model (2D-EPM) with the effective plate properties obtained from the constitutive analysis of unit cell. The accuracy of 2D-EPM is verified by comparing with the displacement, natural frequencies, and buckling results from 3D-FEM under different boundary conditions. Then, the influence of geometric parameters and layup configurations on the effective performances of CCCP are investigated. Finally, the buckling loads and natural frequencies of bidirectional CCCP are compared with those of CCCP by using the present model. The present model is particularly useful in the early design stage of CCCP where many design trade-offs need to be made over a vast design space in terms of material selection, ply angles, and geometric parameters.     

Strength Capacity and Failure Mode of Shear Connectors Suitable for Composite Cold Formed Steel Beams: Numerical Study

In this paper, the findings of numerical modeling of the composite action between normal concrete and Cold-Formed Steel (CFS) beams are presented. To obtain comprehensive structural behavior, the numerical model was designed using 3-D brick components. The simulation results were correlated to the experimental results of eight push tests, using three types of innovative shear connectors in addition to standard headed stud shear connectors, with two different thicknesses of a CFS channel beam. The proposed numerical model was found to be capable of simulating the failure mode of the push test as well as the behavior of shear connectors in order to provide composite action between the cold-formed steel beam and concrete using the concrete damaged plasticity model.     

Study on Structural Design and Manufacturing of Sandwich Composite Floor for Automotive Structure

In this work, structural design and manufacturing of sandwich composite floor for automobile was performed. The tensile and compression strength of specimen were investigated. Based on this, structural design of floor board was performed. The sandwich composite floor board are subject to payload. The maximum load was analyzed in consideration of the safety factor. The structural design and analysis were performed in consideration of applied load. The finite element analysis method was applied to investigate structural safety. The stress, displacement, and buckling analysis was carried out. Through the structural analysis, it was confirmed that the designed floor board structure is safety. Based on the result, the manufacturing of prototype was conducted. Finally, test and evaluation of composite floor board was performed.     

Edgewise Compressive Behavior of Composite Structural Insulated Panels with Magnesium Oxide Board Facings

Edgewise compression response of a composite structural insulated panel (CSIP) with magnesium oxide board facings was investigated. The discussed CSIP is a novel multifunctional sandwich panel introduced to the housing industry as a part of the wall, floor, and roof assemblies. The study aims to propose a computational tool for reliable prediction of failure modes of CSIPs subjected to concentric and eccentric axial loads. An advanced numerical model was proposed that includes geometrical and material nonlinearity as well as incorporates the material bimodularity effect to achieve accurate and versatile failure mode prediction capability. Laboratory tests on small-scale CSIP samples of three different slenderness ratios and full-scale panels loaded with three different eccentricity values were carried out, and the test data were compared with numerical results for validation. The finite element (FE) model successfully captured CSIP’s inelastic response in uniaxial compression and when flexural action was introduced by eccentric loads or buckling and predicted all failure modes correctly. The comprehensive validation showed that the proposed approach could be considered a robust and versatile aid in CSIP design.     

Comparison of Failure for Thin-Walled Composite Columns

The novelty of this paper, in relation to other thematically similar research papers, is the comparison of the failure phenomenon on two composite profiles with different cross-sections, using known experimental techniques and advanced numerical models of composite material failure. This paper presents an analysis of the failure of thin-walled structures made of composite materials with top-hat and channel cross-sections. Both experimental investigations and numerical simulations using the finite element method (FEM) are applied in this paper. Tests were conducted on thin-walled short columns manufactured of carbon fiber reinforced polymer (CFRP) material. The experimental specimens were made using the autoclave technique and thus showed very good strength properties, low porosity and high surface smoothness. Tests were carried out in axial compression of composite profiles over the full range of loading—up to total failure. During the experimental study, the post-buckling equilibrium paths were registered, with the simultaneous use of a Zwick Z100 universal testing machine (UTM) and equipment for measuring acoustic emission signals. Numerical simulations used composite material damage models such as progressive failure analysis (PFA) and cohesive zone model (CZM). The analysis of the behavior of thin-walled structures subjected to axial compression allowed the evaluation of stability with an in-depth assessment of the failure of the composite material. A significant effect of the research was, among others, determination of the phenomenon of damage initiation, delamination and loss of load-carrying capacity. The obtained results show the high qualitative and quantitative agreement of the failure phenomenon. The dominant form of failure occurred at the end sections of the composite columns. The delamination phenomenon was observed mainly on the outer flanges of the structure.     

Analytical Model and Numerical Analysis of Composite Wrap System Applied to Steel Pipeline

Composite overwraps are a cost-effective repair technology, appropriate for corrosion defects, dents, and gouges for both onshore and offshore steel pipelines. The main benefit of polymer-based sleeves is safe installation without taking the pipeline out of service. This paper presents a new calculation procedure proposed in the form of an algorithm for the sizing of composite repairs of corroded pipelines when the sleeve is applied at zero internal pressure. The main objective of the presented methodology is determination of the effective thickness of the composite repair without its overestimation or underestimation. The authors used a non-linear finite element method with constitutive models allowing analysis of the steel, putty, and composite structures. The validation of the results of numerical computations compared to the experimental ones showed an appropriate agreement. The numerical calculations were applied to compare the analytical results in relation to those obtained by the standards ASME PCC-2 or ISO/TS 24817. The comparison showed that the proposed solution confirmed its effectiveness in reducing the thickness of the sleeve significantly, thus, showing that the current industrial standards provide a considerably excessive composite wrap around the steel pipe corroded area, which leads to an unnecessary increase in the repair costs.     

Failure Analysis and Prevention of Extraction Column for Methyl Methacrylate Production: Application of the ‘Safety Design’ Concept

To ensure safety and prevent failure of engineering equipment throughout its lifespan, the concept of ‘Safety Design’ is proposed, which covers all the cradle-to-grave phases of engineering equipment, considers at least ten essential factors of failure causes, and conducts root cause analysis at three different scales, in order to proactively control the safety risks before the occurrence of failure rather than passively conduct the remedial measures after failure. Herein, in order to demonstrate how to implement this effective and efficient concept in engineering practice, a case study of failure analysis and prevention is addressed on the extraction column in the production line for methyl methacrylate. Based on the analysis results, the causes were finally determined to be all derived from the stages before operation, including inappropriate design, limited quality inspection of fabrication and installation. Pertinent countermeasures were then proposed from the ‘Safety Design’ point of view, which would not only solve the failure problem for this sole equipment but also contribute to safety risk control of other engineering equipment before operation.     

Computational Analysis of Mechanical Performance for Composite Polymer Biodegradable Stents

Bioresorbable stents (BRS) represent the latest generation of vascular scaffolds used for minimally invasive interventions. They aim to overcome the shortcomings of established bare-metal stents (BMS) and drug-eluting stents (DES). Recent advances in the field of bioprinting offer the possibility of combining biodegradable polymers to produce a composite BRS. Evaluation of the mechanical performance of the novel composite BRS is the focus of this study, based on the idea that they are a promising solution to improve the strength and flexibility performance of single material BRS. Finite element analysis of stent crimping and expansion was performed. Polylactic acid (PLA) and polycaprolactone (PCL) formed a composite stent divided into four layers, resulting in sixteen unique combinations. A comparison of the mechanical performance of the different composite configurations was performed. The resulting stresses, strains, elastic recoil, and foreshortening were evaluated and compared to existing experimental results. Similar behaviour was observed for material configurations that included at least one PLA layer. A pure PCL stent showed significant elastic recoil and less shortening compared to PLA and composite structures. The volumetric ratio of the materials was found to have a more significant effect on recoil and foreshortening than the arrangement of the material layers. Composite BRS offer the possibility of customising the mechanical behaviour of scaffolds. They also have the potential to support the fabrication of personalised or plaque-specific stents.     

A Review of Finite Element Analysis and Artificial Neural Networks as Failure Pressure Prediction Tools for Corroded Pipelines

This paper discusses the capabilities of artificial neural networks (ANNs) when integrated with the finite element method (FEM) and utilized as prediction tools to predict the failure pressure of corroded pipelines. The use of conventional residual strength assessment methods has proven to produce predictions that are conservative, and this, in turn, costs companies by leading to premature maintenance and replacement. ANNs and FEM have proven to be strong failure pressure prediction tools, and they are being utilized to replace the time-consuming methods and conventional codes. FEM is widely used to evaluate the structural integrity of corroded pipelines, and the integration of ANNs into this process greatly reduces the time taken to obtain accurate results.     

Failure Analysis of Hat-Stringer-Stiffened Aircraft Composite Panels under Four-Point Bending Loading

Hat-stringer-stiffened composite panels have been widely used in aircrafts. Accurate failure analysis of them is important for the safety and integrity of the fuselage. During the service period, these panels will bear not only the lateral force caused by the bending of fuselage, but also the radial pressure caused by the internal and external differential pressure during the take-off and landing of the aircraft. However, the latter case lacks investigation. Therefore, experimental and numerical studies for the static and fatigue failure of hat-stringer-stiffened composite panels under four-point bending loading have been performed in this work. To accurately predict the fatigue failure, a novel theoretical model has been proposed based on the fatigue damage theory. In addition, a user-defined subroutine USDFLD is developed for the implementation of the proposed theoretical model in Abaqus. Experimental results show that the main failure modes are the delamination of the skin and debonding between the girder flange and the skin. The experimental average value of the initial debonding load and displacement in static tests are 897.3 N and 10.8 mm, respectively. Predictions exhibit good agreement with experimental results with relative errors within 10%. Experimental average fatigue failure life of the specimens is 33,085 cycles, which is also close to the prediction with relative errors within 10%. This indicates the reliability and applicability of the established theoretical model and numerical method for predicting the failure of hat-shaped girder structures.     

Seismic Analysis and Design of Composite Shear Wall with Stiffened Steel Plate and Infilled Concrete

Several experiments are conducted to investigate the seismic behavior of composite shear walls because of their advantages compared to traditional reinforced concrete (RC) walls. However, the numerical studies are limited due to the complexities for the steel and concrete behaviors and their interaction. This paper presents a numerical study of composite shear walls with stiffened steel plates and infilled concrete (CWSC) using ABAQUS. The mechanical mechanisms of the web plate and concrete are studied. FE models are used to conduct parametric analysis to study the law of parameters on the seismic behaviour. The finite element (FE) model shows good agreement with the test results, including the hysteresis curves, failure phenomenon, ultimate strength, initial stiffness, and ductility. The web plate and concrete are the main components to resist lateral force. The web plate is found to contribute between 55% and 85% of the lateral force of wall. The corner of web plate mainly resists the vertical force, and the rest of web plate resists shear force. The concrete is separated into several columns by stiffened plates, each of which is independent and resisted vertical force. The wall thickness, steel ratio, and shear span ratio have the greatest influence on ultimate bearing capacity and elastic stiffness. The shear span ratio and axial compression ratio have the greatest influence on ductility. The test and analytical results are used to propose formulas to evaluate the ultimate strength capacity and stiffness of the composite shear wall under cyclic loading. The formulas could well predict the ultimate strength capacity reported in the literature.     

A Two-Dimensional Model for Pin-Load Distribution and Failure Analysis of Composite Bolted Joints

Multibolt composite joints are widely used in aircraft structures. The determination of the pin-load distribution among the bolts is a critical step in the failure prediction of bolted joints. In this paper, a two-dimensional model of the multibolt composite structure is established for the pin-load distribution analysis. Its accuracy is validated by experimental results and the results from a 3D finite element model. Based on the determined pin-load distribution, FE models for a laminated plate with three-row fastener joints are built for failure prediction. Hashin stress criteria and the degradation guidelines of the material stiffness with respect to the different failure modes proposed by Tserpes are applied for the failure evaluation and the material degradation, respectively. The failure location and ultimate load are well predicted, which further validates the effectiveness and applicability of the proposed model for the pin-load distribution analysis.     

Failure Mode Analysis of Aluminium Alloy 2024-T3 in Double-Lap Bolted Joints with Single and Double Fasteners; A Numerical and Experimental Study

This paper aims to study the mechanical behaviour and failure mode of Al 2024-T3 in double-lap bolted joints. To accomplish this, the effect of geometric parameters was investigated in both configurations of single and double fasteners. Using ABAQUS/Standard, a three-dimensional finite element model was developed and verified against the experimental results of the joints loaded in tension. In general, double bolt joints were found to have greater load carrying capacities than single bolt joints (by 40%–49%). In single bolt joints, the plate width had insignificant effect on the behaviour of the joint under tensile loading; whereas, increasing the distance of the hole from the edge, considerably enhanced the strength of the joint. In double bolt joints, changing the edge distance had almost no effect on the behaviour of the joint. However, increasing the plate width from 25.4 to 30 mm increased the load carrying capacity by 28%. This study showed that in single bolt connections, with increasing the edge distance, the failure mode can favourably shift from shear-out to bearing. Also, double bolt joints with wider plates (increased width) can beneficially shift the failure mode from net-tension to bearing. The geometric parameters were found to play an important role in controlling the failure mode so that catastrophic failure modes of net-tension and shear-out can be prevented in bolted joint.     

Study on Structural Design and Analysis of Composite Boat Hull Manufactured by Resin Infusion Simulation

In this paper, structural design and analysis of a composite boat hull was performed. A resin transfer molding manufacturing method was adopted for manufacturing the composite boat hull. The RTM process is an advanced composite manufacturing method that allows a much higher quality product than the hand lay-up process, and less manufacturing cost compared to the autoclave method. Therefore, the RTM manufacturing method was adopted. The mechanical properties of the various aramid fibers and polyester resin were investigated. Based on this, structural design of boat hull was performed using aramid fiber or polyester. After structural design, the optimized resin infusion analysis for RTM manufacturing method was performed. Through the resin infusion analysis, it is confirmed that the designed location of resin injection and outlet is acceptable for manufacturing.     

Fatigue Evaluation for Innovative Excavator Arms Made of Composite Material

This research reports the results related to the evaluation of the fatigue phenomenon of the arms of a medium–large excavator made of composite material (carbon fiber) instead of the classic constructional steel S355 (UNI EN 10025-3). In the numerical sizing phase, it was obtained that the overall weight of the excavator’s arms made of composite material is about 35% of the same components made of steel, obviously with equal performance in terms of the safety static coefficient, rigidity, and critical buckling load. The evaluation of the fatigue behaviour (assuming 5.25 × 10⁶ load cycles) applied for each load condition analyzed (levelling from the maximum distance to the minimum, lifting at the maximum distance, lifting at the minimum distance and rotation) shows the magnitude of the safety coefficients both related to the allowable stress and relative to the number of cycles acceptable. The assumption instead of combined cycles (involving one or more load conditions) leads to a significant reduction in the magnitude of the safety coefficients. The implementation of a loading cycle plan resulting from the different load conditions must be reliably assessed to evaluate as accurately as possible the fatigue behavior of the excavator arms made of composite material.