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.     

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.     

Tests and Numerical Study of Single-Lap Thermoplastic Composite Joints Bolted by Countersunk

Tensile tests were carried out to investigate the effect of stacking sequences on the bearing strength of single-lap thermoplastic composite countersunk bolted joints. A 3D elastoplastic model was built based on a plastic theory for numerical analysis. The damage initiation was judged based on LaRC05 criteria, and the damage propagation was described by using a nonlinear, gradual unloading method based on crack band theory. The accuracy of the present model was validated by comparing the numerical results to those from the tests. The test results showed that the effects of stacking sequences on the ultimate bearing strength and the 2% offset bearing strength are limited. Moreover, the numerical results depicted that the ultimate bearing strength and the 2% offset bearing strength reduce when the bolt-tightening torque or the bolt–hole clearance is increased.     

Modeling Progressive Damage and Failure of Single-Lap Thin-Ply-Laminated Composite-Bolted Joint Using LaRC Failure Criterion

Thin-ply composite failure modes also significantly differ from conventional ply composite failure modes, with the final failure mechanism switching from irregular progressive failure to direct fracture characterized by a uniform fracture with the reduction of the ply thickness. When open holes and bolt joints are involved, thin-ply-laminated composites exhibit more complex stress states, damage evolution, and failure modes. Compared to the experimental study of thin-ply-laminated composite-bolted joints, there are few reports about numerical analysis. In order to understand the damage evolution and failure mechanism of thin-ply-laminated composites jointed by single-lap bolt, a progressive damage model based on three-dimensional (3D) LaRC failure criterion combined with cohesive element is constructed. Through an energy-based damage evolution method, this model can capture some significant mechanical characteristics in thin-ply-laminated structures, such as the in situ effect, delamination inhibition, and fiber compressive kinking failure. The comparisons between the numerical predictions and experimental observations are made to verify the accuracy of the proposed model. It is found that the predicted stress-displacement curves, failure modes, damage morphologies, etc., are consistent with the experimental results, indicating that the presented progressive damage analysis method displays excellent accuracy. The predicted stress at the onset of delamination is 50% higher than that of the conventional thick materials, which is also consistent with experimental results. Moreover, the numerical model provides evidence that the microstructure of thin-ply-laminated composite performs better in uniformity, which is more conducive to inhibiting the intra-layer damage and the expansion of delamination damage between layers. This study on the damage inhibition mechanism of thin-ply provides a potential analytical tool for evaluating damage tolerance and bearing capabilities in thin-ply-laminated composite-bolted joints.     

On the Calibration of a Numerical Model for Concrete-to-Concrete Interface

The study was devoted to the numerical modelling of concrete-to-concrete interfaces. Such an interface can be found in many modern composite structures, so proper characterisation of its behaviour is of great importance. A strategy for calibration of a model based on cohesive finite elements and the elastic-damage traction–separation constitutive law available by default in the Abaqus code was proposed. Moreover, the default interface material model was enhanced with the user-field-variables subroutine to include a real strength envelope for such interfaces. Afterwards, the modelling approach was validated with numerical simulation of the most popular tests for determining the strength characteristics of concrete-to-concrete interfaces: three-point bending beam with a notch, splitting bi-material cubic specimens, and slant-shear tests. The results of own pilot studies were used as well as those reported by other researchers. The performed simulations proved the accuracy of the proposed modelling strategy (the mean ratio of ultimate forces obtained with numerical models and from experiments was equal to 1.01). Furthermore, the presented examples allowed us to better understand the basic test methods for concrete interfaces and the observed mechanisms of failure during them.     

A Study on the In-Plane Shear-after-Impact Properties of CFRP Composite Laminates

Impact loading on carbon fiber reinforced polymer matrix (CFRP) composite laminates can result in a significant reduction in their residual properties, and the (ShAI) properties of the composite material are essential to obtain the material allowable values of the shear dominated composite structures. In order to obtain the ShAI properties of the composite material in pure shear stress at a coupon level, this study presents theoretical, experimental, and numerical methods and analysis work on the in-plane shear and ShAI properties of the composite laminates. Theoretically, a method of sizing the composite specimen loading in shear is developed through comparing the load values due to buckling and the material failure. Following this, both impact tests using the drop-weight method and ShAI tests using the picture frame test method are conducted, and the influences of the impact energies on the impact damage and the residual ShAI values are evaluated. Moreover, a progressive failure finite element model based on the Hashin’s failure criterion and the cohesive zone model is developed, and a two-step dynamic analysis method is performed to simulate the failure process of the composite laminates under impact loading and ShAI loading. It is found that the impact damage with the cut-off energy, 50 J, causes a 26.8% reduction in the residual strength and the residual effective shear failure strain is about 0.0132. The primary reason of the shear failure is the propagation of both the matrix tensile failure and interlaminar delamination. It can be concluded that the proposed theoretical, experimental, and numerical methods are promising factors to study the ShAI properties of the composite materials.     

Experimental and Numerical Investigation of Intact,Defective and Repaired Countersunk Composite Joints under Tensile Loading

Bolted joints are commonly used for assembling carbon fiber/resin composite structures. Since drilling may generate defects at hole edges which affect mechanical properties, it is of great engineering significance to develop proper repair methods to restore the mechanical properties of the defective parts. However, there are few studies on hole edge defects and their repair methods. Therefore, a novelty short fiber filling repair method was proposed to repair defective holes in this study. The mechanical properties of intact, defective and repaired countersunk composite joints were compared and investigated. Experimental tensile tests showed that defective joints had lower initial stiffness and failure loads compared to intact joints, while the mechanical properties were effectively restored after repair. Three-dimensional finite element models were also established to analyze the damage process of the joints. Results of numerical modelling were consistent with the experimental results. The simulations showed that changes in contact behaviors and local deformations caused by hole edge defects led to the low initial stiffness and stiffness transition point of the joint, while this phenomenon was reduced after repair. Additionally, despite different joint types, laminate failure mainly occurred around the hole and countersink.     

Stating Failure Modelling Limitations of High Strength Sheets: Implications to Sheet Metal Forming

This article discusses the fracture modelling accuracy of strain-driven ductile fracture models when introducing damage of high strength sheet steel. Numerical modelling of well-known fracture mechanical tests was conducted using a failure and damage model to control damage and fracture evolution. A thorough validation of the simulation results was conducted against results from laboratory testing. Such validations show that the damage and failure model is suited for modelling of material failure and fracture evolution of specimens without damage. However, pre-damaged specimens show less correlation as the damage and failure model over-predicts the displacement at crack initiation with an average of 28%. Consequently, the results in this article show the need for an extension of the damage and failure model that accounts for the fracture mechanisms at the crack tip. Such extension would aid in the improvement of fracture mechanical testing procedures and the modelling of high strength sheet metal manufacturing, as several sheet manufacturing processes are defined by material fracture.     

Influence of the Arrangement of Mechanical Fasteners on the Static Strength and Fatigue Life of Hybrid Joints

This paper presents the results of experimental research and numerical calculations regarding the static strength and fatigue life of hybrid joints. In the experiments, specimens built as single-lap adhesive–mechanical joints (hybrid joints) were tested. In a two-stage process of the failure of the hybrid joints, the adhesive joint was damaged first. Therefore, it was assumed that the assembly of fasteners closer to the edge of the overlap (beyond the ranges recommended for mechanical joints) limits the negative impact of the peeling phenomenon on the strength and performance properties of hybrid joints. The specimens used in the experiments were prepared from composite elements (i.e., carbon fiber-reinforced polymer (CFRP)), as well as from the aluminum alloy 2024T4. Because the detection of fatigue damage in composite materials is a complex problem, computed tomography was used to evaluate the degradation of the composite material. Experimental and numerical comparative analyses of the static strength and fatigue life of hybrid joints with adhesive and mechanical joints confirmed the assumptions made.     

Experimental Study of Aluminium-Timber Composite Bolted Connections Strengthened with Toothed Plates

This paper presents the first experimental study of the load-slip behaviour of aluminium-timber composite bolted connections reinforced with toothed plates. The effectiveness of the strengthening was evaluated in laboratory push-out tests. The push-out test samples consisted of laminated veneer lumber panels, aluminium alloy I-beams, and bolts (grade 8.8 10 mm × 125 mm and 12 mm × 135 mm bolts, grade 5.8 10 mm × 125 mm and 12 mm × 135 mm bolts). A group of 16 specimens had toothed plates as additional reinforcement, while 16 specimens had no reinforcement. The impact of the bolt diameter (10 and 12 mm) and bolt grade (5.8 and 8.8) on the behaviour of the connections was also analysed. The values of the ultimate load and the slip modulus for the bolted connections with grade 8.8 10 mm and 12 mm bolts and with grade 5.8 12 mm bolts reinforced by toothed-plate connectors were comparable to the values for the non-reinforced connections. This was because, in the case of grade 8.8 10 mm × 125 mm and 12 mm × 135 mm bolts and grade 5.8 12 mm × 135 mm bolts, the laminated veneer lumber (LVL) slabs split both in the reinforced and non-reinforced connections. The toothed-plate connectors reduced timber destruction in the bearing zones in the LVL slabs. However, they did not protect the LVL slabs against splitting. Therefore, the impact of the toothed plate connectors on the stiffness and strength of the bolted connections with grade 8.8 10 mm and 12 mm bolts and with grade 5.8 12 mm bolts analysed in this paper was found to be negligible. In the case of grade 5.8 10 mm bolts, the LVL slabs did not split. The mean slip modulus k_0.6 of the connections with grade 5.8 10 mm bolts reinforced with toothed plate connectors was 2.9 times higher than that of the non-reinforced connections. However, the strength of the connections with grade 5.8 10 mm bolts was 1.2 times lower after reinforcing. This was because the shanks of the bolts were sheared faster in the reinforced connections than in the non-reinforced connections as a result of the bolt shanks being under the bearing pressure of the aluminium flange, the LVL slab, and the toothed-plate flange. This situation did not occur for the remaining connections because they had a higher strength (grade 8.8 bolts) or a larger diameter (12 mm), and their bolts were less prone to cutting off. The investigated load–slip curves of the reinforced bolted connections can be used for designing and numerical modelling of aluminium-timber composite beams with this type of connection.     

Experimental and Numerical Investigation into Failure Modes of Tension Angle Members Connected by One Leg

This paper presents the results of experimental and numerical tests on angle members connected by one leg with a single row of bolts. This study was designed to determine which failure mode governs the resistance of such joints: net section rupture or block tearing rupture. Experimental tests were insufficient to completely identify the failure modes, and it was necessary to conduct numerical simulations. Finite element analysis of steel element resistance based on rupture required advanced material modelling, taking into account ductile initiation and propagation of fractures. This was realised using the Gurson–Tvergaard–Needleman porous material model, which allows for analysis of the joint across the full scope of its behaviour, from unloaded state to failure. Through experimental testing and numerical simulations, both failure mechanisms (net section and block tearing) were examined, and an approach to identify the failure mode was proposed. The obtained results provided experimental and numerical evidence to validate the strength function used in design standards. Finally, the obtained results of the load capacity were compared with the design procedures given in the Eurocode 3′s current and 2021 proposed editions.     

Experimental and Finite Element Study on Bending Performance of Glulam-Concrete Composite Beam Reinforced with Timber Board

In this research, experimental research and finite element modelling of glulam-concrete composite (GCC) beams were undertaken to study the flexural properties of composite beams containing timber board interlayers. The experimental results demonstrated that the failure mechanism of the GCC beam was the combination of bend and tensile failure of the glulam beam. The three-dimensional non linear finite element model was confirmed by comparing the load-deflection curve and load-interface slip curve with the experimental results. Parametric analyses were completed to explore the impacts of the glulam beam height, shear connector spacing, timber board interlayer thickness and concrete slab thickness on the flexural properties of composite beams. The numerical outcomes revealed that with an increase of glulam beam height, the bending bearing capacity and flexural stiffness of the composite beams were significantly improved. The timber boards were placed on top of the glulam members and used as the formwork for concrete slab casting. In addition, the flexural properties of composite beams were improved with the increase of the timber board thickness. With the elevation of the shear connector spacing, the ultimate bearing capacity and bending stiffness of composite beams were decreased. The bending bearing capacity and flexural rigidity of the GCC beams were ameliorated with the increase of concrete slab thickness.     

A Robust Numerical Methodology for Fatigue Damage Evolution Simulation in Composites

Composite materials, like metals, are subject to fatigue effects, representing one of the main causes for component collapse in carbon fiber-reinforced polymers. Indeed, when subject to low stress cyclic loading, carbon fiber-reinforced polymers exhibit gradual degradation of the mechanical properties. The numerical simulation of this phenomenon, which can strongly reduce time and costs to market, can be extremely expensive in terms of computational effort since a very high number of static analyses need to be run to take into account the real damage propagation due the fatigue effects. In this paper, a novel cycle jump strategy, named Smart Cycle strategy, is introduced in the numerical model to avoid the simulation of every single cycle and save computational resources. This cycle jump strategy can be seen as an enhancement of the empirical model proposed by Shokrieh and Lessard for the evaluation of the fatigue-induced strength and stiffness degradation. Indeed, the Smart Cycle allows quickly obtaining a preliminary assessment of the fatigue behavior of composite structures. It is based on the hypothesis that the stress redistribution, due to the fatigue-induced gradual degradation of the material properties, can be neglected until sudden fiber and/or matrix damage is verified at element/lamina level. The numerical procedure has been implemented in the commercial finite element code ANSYS MECHANICAL, by means of Ansys Parametric Design Languages (APDL). Briefly, the Smart Cycle routine is able to predict cycles where fatigue failure criteria are likely to be satisfied and to limit the numerical simulation to these cycles where a consistent damage propagation in terms of fiber and matrix breakage is expected. The proposed numerical strategy was preliminarily validated, in the frame of this research study, on 30° fiber-oriented unidirectional coupons subjected to tensile–tensile fatigue loading conditions. The numerical results were compared with literature experimental data in terms of number of cycles at failure for different percentage of the static strength. Lastly, in order to assess its potential in terms of computational time saving on more complex structures and different loading conditions, the proposed numerical approach was used to investigate the fatigue behavior of a cross-ply open-hole composite panel under tension–tension fatigue loading conditions.     

Structural Response of Bonded Joints between FRP Composite Strips and Steel Plates

This paper presents the outcomes of an experimental and numerical study performed on epoxy-bonded single lap joints (SLJs) between carbon fiber-reinforced polymer (CFRP) composite strips and steel elements. For the experimental program, 34 specimens were prepared by varying the type of the composite strip and the type of adhesives and their thicknesses; all specimens were loaded in axial tension up to failure. The specific failure mechanisms were identified and commented on the basis of the performed tests, and the load–displacement curves were plotted. Additionally, the strain distributions along the bond lengths at different load stages, the shear stress–displacements (slip) variations and the stress–strain distributions for the CFRP strips were plotted and investigated. The numerical simulations, based on 3D finite element method (FEM) analysis, provided consistent results, in good agreement with the experimental ones for all parameters that were investigated and discussed in this paper.     

Experimental and Numerical Study of Low-Velocity Impact and Tensile after Impact for CFRP Laminates Single-Lap Joints Adhesively Bonded Structure

To investigate the mechanical behavior of the single-lap joints (SLJs) adhesively bonded structure of carbon fiber reinforced polymer (CFRP) laminates under the low-velocity impact (LVI) and tensile-after impact (TAI), tests and simulations were carried out. A finite element model (FEM) was established based on the cohesive zone model (CZM) and Hashin criterion to predict the damage evolution process of adhesive film, intra- and inter-laminar of the SLJs of CFRP laminates, and its effectiveness was verified by experiments. Moreover, three different overlap lengths (20 mm, 30 mm, and 40 mm) and four different impact energies (Intact joint, 10 J, 20 J, and 30 J) are considered in the present study. Finally, the effects of different impact energies and overlap lengths on the residual strength of SLJs after impact were discussed. The results divulged that numerical results of impact and TAI processes of SLJs were in good agreement with experiment results. During the impact process, the damage of the laminates was primarily fiber and matrix tensile damage, whereas the adhesive film was damaged cohesively; the areas of damage increased with the increase of impact energy, and the normal stress of the adhesive film expanded from the edge to the middle region with the increase of impact force. The influence of LVI on SLJs adhesively bonded structures was very significant, and it is not effective to obtain a higher impact resistance by increasing the overlap length. For the tensile process, the failure mode of TAI of the SLJs was interface failure, the surplus strength of the SLJs gradually decreased with the increase of the impact energy because of the smaller overlap length, the overlap length more than 30 mm, and the low energy impact has almost no effect on the residual strength of the SLJs.     

Effect of Hole Arrangement on Failure Mechanism of Multiple-Hole Fiber Metal Laminate under On-Axis and Off-Axis Loading

Mechanical joints are commonly required in structures made of fiber metal laminate (FML), which pose a threat due to multi-site stress concentrations at rivet or bolt holes. Thus, for a reasonably designed FML joint, it is essential to characterize the failure mechanism of multiple-hole FML; however, little information about this has been found in open literature. In the present work, influences of hole arrangement and loading strategy (on-axis or off-axis) on the failure mechanism of multiple-hole FML were investigated, by performing finite element analyses and energy dissipation analyses with elastoplastic progressive damage models that took curing stress into account. Six types of specimens with holes arranged in parallel and staggered forms were designed, whose geometrical parameters were in strict accordance with those specified for composites joints. It indicated that the stress distribution, gross/net notched strength, critical fracture path, and damage evaluation process were only slightly influenced by the hole number and hole arrangement. On the other hand, they were strongly influenced by the loading strategy, due to the transition of failure domination. Results presented here can provide evidence for introducing design regulations of composite joints into the more hybrid FML, and for reasonably determining its multiple-hole strength merely based on the sing-hole specimen.     

Screw behavior in large diameter slewing bearing assemblies: numerical and experimental analyses

This paper investigates the behavior of large diameter bearing bolted joint in order to evaluate fatigue resistance of the screws. Based on experimental results, a sector of a slewing bearing is modeled using 3D finite elements. The model is built via hypothesis of sine-distributed efforts on the roller tracks. The simulations are carried out for the most loaded screw, which is located in the symmetry plane. Experimental measures on equipped screws are checked against numerical 3D simulations. This validates the numerical modeling method. Then the numerical model is used to evaluate the influence of several geometrical and physical parameters. The preload intensity reveals to be the major parameter. The bushes’ height affects load filtering and improves fatigue strength of the screws. The height of the mounting tubes smoothes potential stiff points. The friction coefficient between the ring and the mounting is investigated as well. Eventually, several observations are made which lead to design recommendations for fatigue sizing of the slewing bearing screwed joints.     

Low- and High-Cycle Fatigue Behavior of FRCM Composites

This paper describes methods, procedures, and results of cyclic loading tensile tests of a PBO FRCM composite. The main objective of the research is the evaluation of the effect of low- and high-cycle fatigue on the composite tensile properties, namely the tensile strength, ultimate tensile strain, and slope of the stress–strain curve. To this end, low- and high-cycle fatigue tests and post-fatigue tests were performed to study the composite behavior when subjected to cyclic loading and after being subjected to a different number of cycles. The results showed that the mean stress and amplitude of fatigue cycles affect the specimen behavior and mode of failure. In high-cycle fatigue tests, failure occurred due to progressive fiber filaments rupture. In low-cycle fatigue, the stress–strain response and failure mode were similar to those observed in quasi-static tensile tests. The results obtained provide important information on the fatigue behavior of PBO FRCM coupons, showing the need for further studies to better understand the behavior of existing concrete and masonry members strengthened with FRCM composites and subjected to cyclic loading.     

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.