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Bergan, Andrew C.

Publications and source records attributed to Bergan, Andrew C..

Comparison of Design Tools for Stress Analysis of Adhesively Bonded Joints

Analytical or semi-analytical models for stress analysis have long been a part of initial adhesive bond design and sizing. Even with the rise of general finite element software and methods, these design models have still remained a preferred method for fast and simple joint analysis. While these methods can yield fairly representative results, the models are constructed on the foundation of geometrical and material simplifications or assumptions that allow closed form or semi-closed form solutions. This study outlines the major differences in basic assumptions for three common design software packages under use at NASA, and shows the ramifications these assumptions in a few exemplar bonded joints.

Composites↗

Modeling Fiber Kinking at the Microscale and Mesoscale

A computational micromechanics (CMM) model is employed to interrogate the assumptions of a recently developed mesoscale continuum damage mechanics (CDM) model for fiber kinking. The CMM model considers an individually discretized three dimensional fiber and surrounding matrix accounting for nonlinearity in the fiber, matrix plasticity, fiber/matrix interface debonding, and geometric nonlinearity. Key parameters of the CMM model were measured through experiments. In particular, a novel experimental technique to characterize the in situ longitudinal compressive strength of carbon fibers through indentation of micropillars is presented. The CDM model is formulated on the basis of Budiansky's fiber kinking theory (FKT) with a constitutive deformation-decomposition approach to alleviate mesh size sensitivity. In contrast to conventional mesoscale CDM models that prescribe a constitutive response directly, the response of the proposed model is an outcome of material nonlinearity and large rotations of the fiber direction following FKT. Comparison of the predictions from the CMM and CDM models shows remarkable correlation in strength, post-peak residual stress, and fiber rotation, with less than 10% difference between the two models in most cases. Additional comparisons are made with several fiber kinking models proposed in the literature to highlight the efficacy of the two models. Finally, the CMM model is exercised in parametric studies to explore opportunities to improve the longitudinal compression strength of a ply through the use of nonconventional microstructures.

Herraez, Miguel↗

Validation of a Mesoscale Fiber Kinking Model Through Test and Analysis of Double Edge Notch Compression Specimens

Tests and analyses were conducted on a series of geometrically-scaled double edge notch compression specimens to validate the capability of the fiber-kinking model in the NASA continuum damage mechanics code for progressive damage analysis, CompDam. The tests and analyses focused on the fiber-kinking damage mechanism, which is of critical importance for predicting accurately longitudinal compression failure in carbon fiber reinforced polymer laminates. The fiber-kinking model in CompDam was augmented with a new capability to represent a hardening response once a kink band has fully formed, enabling prediction of band broadening. Correlation of the test and analysis results showed agreement in stiffness and strength with less than 10% error. The analysis predicts the same sequence of events leading to ultimate failure that was found in the test. The overall excellent correlation in terms of stiffness, strength, and failure process validates the capability of the model for predicting longitudinal compression failure in notched laminates with cross-ply layups.

Bergan, Andrew C.↗

Development of a Mesoscale Finite Element Constitutive Model for Fiber Kinking

A mesoscale finite element material model is proposed to analyze structures that fail by the fiber kinking damage mode. To evaluate the assumptions of the mesoscale model, the results were compared with those of a high-fidelity micromechanical model. A direct comparison between the two models shows remarkable correlation, indicating that the key features of the fiber kinking phenomenon are appropriately accounted for in the mesoscale model. The mesoscale model is applied to structural analysis cases to demonstrate the capabilities of the model. A verification study is conducted with an unnotched compression specimen and preliminary validation is demonstrated with a notched compression specimen. The results show that the model is successful at representing the kinematics of fiber kinking while at the same time highlighting the need for further verification and validation.

Bergan, Andrew C.↗

In-Situ Observations of Longitudinal Compression Damage in Carbon-Epoxy Cross Ply Laminates Using Fast Synchrotron Radiation Computed Tomography

The role of longitudinal compressive failure mechanisms in notched cross-ply laminates is studied experimentally with in-situ synchrotron radiation based computed tomography. Carbon/epoxy specimens loaded monotonically in uniaxial compression exhibited a quasi-stable failure process, which was captured with computed tomography scans recorded continuously with a temporal resolutions of 2.4 seconds and a spatial resolution of 1.1 microns per voxel. A detailed chronology of the initiation and propagation of longitudinal matrix splitting cracks, in-plane and out-of-plane kink bands, shear-driven fiber failure, delamination, and transverse matrix cracks is provided with a focus on kink bands as the dominant failure mechanism. An automatic segmentation procedure is developed to identify the boundary surfaces of a kink band. The segmentation procedure enables 3-dimensional visualization of the kink band and conveys the orientation, inclination, and spatial variation of the kink band. The kink band inclination and length are examined using the segmented data revealing tunneling and spatial variations not apparent from studying the 2-dimensional section data.

Bergan, Andrew C.↗

Multiscale Fiber Kinking: Computational Micromechanics and a Mesoscale Continuum Damage Mechanics Models

In this work, the fiber kinking phenomenon, which is known as the failure mechanism that takes place when a fiber reinforced polymer is loaded under longitudinal compression, is studied. A computational micromechanics model is employed to interrogate the assumptions of a recently developed mesoscale continuum damage mechanics (CDM) model for fiber kinking based on the deformation gradient decomposition (DGD) and the LaRC04 failure criteria.

Herraez, Miguel↗

A Numerical Study on the Edgewise Compression Strength of Sandwich Structures with Facesheet-Core Disbonds

Damage tolerant design approaches require determination of critical damage modes and flaw sizes in order to establish nondestructive evaluation detection requirements. A finite element model is developed to assess the effect of circular facesheet-core disbonds on the strength of sandwich specimens subjected to edgewise compressive loads for the purpose of predicting the critical flaw size for a variety of design parameters. Postbuckling analyses are conducted in which an initial imperfection is seeded using results from a linear buckling analysis. Both the virtual crack closure technique (VCCT) and cohesive elements are considered for modeling disbond growth. Predictions from analyses using the VCCT and analyses using cohesive elements are in good correlation. A series of parametric analyses are conducted to investigate the effect of core thickness and material, facesheet layup, facesheet-core interface properties, and curvature on the criticality of facesheet-core disbonds of various sizes. The results from these analyses provide a basis for determining the critical flaw size for facesheet-core disbonds subjected to edgewise compression loads and, therefore, nondestructive evaluation flaw detection requirements for this configuration.

Bergan, Andrew C.↗

A Continuum Damage Mechanics Model to Predict Kink-Band Propagation Using Deformation Gradient Tensor Decomposition

A new model is proposed that represents the kinematics of kink-band formation and propagation within the framework of a mesoscale continuum damage mechanics (CDM) model. The model uses the recently proposed deformation gradient decomposition approach to represent a kink band as a displacement jump via a cohesive interface that is embedded in an elastic bulk material. The model is capable of representing the combination of matrix failure in the frame of a misaligned fiber and instability due to shear nonlinearity. In contrast to conventional linear or bilinear strain softening laws used in most mesoscale CDM models for longitudinal compression, the constitutive response of the proposed model includes features predicted by detailed micromechanical models. These features include: 1) the rotational kinematics of the kink band, 2) an instability when the peak load is reached, and 3) a nonzero plateau stress under large strains.

Bergan, Andrew C.↗

Cohesive Laws for Analyzing Through-Crack Propagation in Cross Ply Laminates

The laminate cohesive approach (LCA) is a methodology for the experimental characterization of cohesive through-the-thickness damage propagation in fiber-reinforced polymer matrix composites. LCA has several advantages over other existing approaches for cohesive law characterization, including: visual measurements of crack length are not required, structural effects are accounted for, and LCA can be applied when the specimen is too small to achieve steady-state fracture. In this work, the applicability of this method is investigated for two material systems: IM7/8552, a conventional prepreg, and AS4/VRM34, a non-crimp fabric cured using an out-of-autoclave process. The compact tension specimen configuration is used to propagate stable Mode I damage. Trilinear cohesive laws are characterized using the fracture toughness and the notch tip opening displacement. Test results are compared for the IM7/8552 specimens with notches machined by waterjet and by wire slurry saw. It is shown that the test results are nearly identical for both notch tip preparations methods, indicating that significant specimen preparation time and cost savings can be realized by using the waterjet to notch the specimen instead of the wire slurry saw. The accuracy of the cohesive laws characterized herein are assessed by reproducing the structural response of the test specimens using computational methods. The applicability of the characterization procedure for inferring lamina fracture toughness is also discussed.

Bergan, Andrew C.↗

Mode I Cohesive Law Characterization of Through-Crack Propagation in a Multidirectional Laminate

A method is proposed and assessed for the experimental characterization of through-the-thickness crack propagation in multidirectional composite laminates with a cohesive law. The fracture toughness and crack opening displacement are measured and used to determine a cohesive law. Two methods of computing fracture toughness are assessed and compared. While previously proposed cohesive characterizations based on the R-curve exhibit size effects, the proposed approach results in a cohesive law that is a material property. The compact tension specimen configuration is used to propagate damage while load and full-field displacements are recorded. These measurements are used to compute the fracture toughness and crack opening displacement from which the cohesive law is characterized. The experimental results show that a steady-state fracture toughness is not reached. However, the proposed method extrapolates to steady-state and is demonstrated capable of predicting the structural behavior of geometrically-scaled specimens.

Bergan, Andrew C.↗

Nonlinear Analysis and Post-Test Correlation for a Curved PRSEUS Panel

The Pultruded Rod Stitched Efficient Unitized Structure (PRSEUS) concept, developed by The Boeing Company, has been extensively studied as part of the National Aeronautics and Space Administration's (NASA s) Environmentally Responsible Aviation (ERA) Program. The PRSEUS concept provides a light-weight alternative to aluminum or traditional composite design concepts and is applicable to traditional-shaped fuselage barrels and wings, as well as advanced configurations such as a hybrid wing body or truss braced wings. Therefore, NASA, the Federal Aviation Administration (FAA) and The Boeing Company partnered in an effort to assess the performance and damage arrestments capabilities of a PRSEUS concept panel using a full-scale curved panel in the FAA Full-Scale Aircraft Structural Test Evaluation and Research (FASTER) facility. Testing was conducted in the FASTER facility by subjecting the panel to axial tension loads applied to the ends of the panel, internal pressure, and combined axial tension and internal pressure loadings. Additionally, reactive hoop loads were applied to the skin and frames of the panel along its edges. The panel successfully supported the required design loads in the pristine condition and with a severed stiffener. The panel also demonstrated that the PRSEUS concept could arrest the progression of damage including crack arrestment and crack turning. This paper presents the nonlinear post-test analysis and correlation with test results for the curved PRSEUS panel. It is shown that nonlinear analysis can accurately calculate the behavior of a PRSEUS panel under tension, pressure and combined loading conditions.

Gould, Kevin↗

Assessment of Damage Containment Features of a Full-Scale PRSEUS Fuselage Panel Through Test and Teardown

An area that shows promise in enhancing structural integrity of aircraft and aerospace structures is the integrally stitched composite technology. The most recent generation of this technology is the Pultruded Rod Stitched Efficient Unitized Structure (PRSEUS) concept developed by Boeing Research and Technology and the National Aeronautics and Space Administration. A joint test program on the assessment of damage containment capabilities of the PRSEUS concept for curved fuselage structures was conducted recently at the Federal Aviation Administration William J. Hughes Technical Center. The panel was subjected to axial tension, internal pressure, and combined axial tension and internal pressure load conditions up to fracture, with a through-the-thickness, two-bay notch severing the central stiffener. For the purpose of future progressive failure analysis development and verification, extensive post failure nondestructive and teardown inspections were conducted. Detailed inspections were performed directly ahead of the notch tip where stable damage progression was observed. These examinations showed: 1) extensive delaminations developed ahead of the notch tip, 2) the extent and location of damage, 3) the typical damage mechanisms observed in composites, and 4) the role of stitching and warp-knitting in the failure mechanisms. The objective of this paper is to provide a summary of results from these posttest inspections.

Bergan, Andrew C.↗