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NASA NTRS1984

Crashworthiness of light aircraft fuselage structures: A numerical and experimental investigation

The dynamic behavior of aircraft fuselage structures subject to various impact conditions was investigated. An analytical model was developed based on a self-consistent finite element (CFE) formulation utilizing shell, curved beam, and stringer type elements. Equations of motion were formulated and linearized (i.e., for small displacements), although material nonlinearity was retained to treat local plastic deformation. The equations were solved using the implicit Newmark-Beta method with a frontal solver routine. Stiffened aluminum fuselage models were also tested in free flight using the UTIAS pendulum crash test facility. Data were obtained on dynamic strains, g-loads, and transient deformations (using high speed photography in the latter case) during the impact process. Correlations between tests and predicted results are presented, together with computer graphics, based on the CFE model. These results include level and oblique angle impacts as well as the free-flight crash test. Comparisons with a hybrid, lumped mass finite element computer model demonstrate that the CFE formulation provides the test overall agreement with impact test data for comparable computing costs.

Nanyaro, A. P.↗

NASA NTRSDate not supplied

Method Development for Experimental Characterization of Dynamic Strength of Aluminum Structures

Space Flight Hardware (SFH) experiences intense vibratory loading during flight, which only lasts a few minutes. When determining the appropriate size of these components to withstand such loading without becoming damaged, standard design practice is to assume that the peak dynamic loads are applied statically. In doing so, the resulting stress is compared against a material strength parameter obtained from a quasi-static experiment. Since the near-peak stresses are only experienced over a small fraction of time in reality, this approach leads to design conservatism that unnecessarily increases structural mass as well as the associated inefficiency and financial cost. In an effort to modernize engineering design standards to appropriately consider the higher practical strength of dynamically loaded structures, this overarching research project seeks to develop an experimental test procedure for quantifying the dynamic strength of metallic alloys as a function of excitation frequency. In the ideal case, the characterization test would include an in-situ method for monitoring the onset and progression of plastic deformation of the test specimen undergoing vibratory loading. These new tests are designed to be high intensity (forcing amplitude), short term (60 seconds at full amplitude), and cyclic in nature (sinusoidal excitation via attached stinger to an otherwise cantilevered beam). In addition, the initial alloy under investigation is 6061 aluminum, due to its wide use and applicability for SFH. Thus far, the primary candidate under development with live-capacity is to track hysteresis behavior of the beam from power dissipation trends, calculated via force (from transducer on excitation stinger) and velocity (measurements from Laser Doppler Vibrometer) data and work to distinguish between elastic and plastic features. As a key component of this ongoing method development, any pseudo-live indication of plasticity could be corroborated against the outcome of a pre-post assessment of damage via macroscopic evaluation of beam geometry (i.e. assessing any permanent change in the beam’s tip deflection). Support for experimental design decisions as well as dynamic strength data from tests with excitation frequencies of 10, 40, and 55 Hz will be discussed. This work contributes to the foundation for a new type of vibration-based characterization experiments and generates initial data on the functional strength of 6061 aluminum under the conditions considered.

vibrations, plastic deformation, aluminum, testing↗

NASA NTRS2002

The Influence of Interfacial Roughness on Fiber Sliding in Oxide Composites with La-Monazite Interphases

Room temperature debonding and sliding of La-Monazite coated fibers is assessed using a composite with a polycrystalline alumina matrix and fibers of several different single crystal (mullite, sapphire) and directionally solidified eutectic (Al2O3/Y3Al5O12 and Al2O3/Y-ZrO2) compositions. These fibers provide a range of residual stresses and interfacial roughnesses. Sliding occurred over a debond crack at the fiber-coating interface when the sliding displacement and surface roughness were relatively small. At large sliding displacements with relatively rough interfaces, the monazite coatings were deformed extensively by fracture, dislocations and occasional twinning, whereas the fibers were undamaged. Dense, fine-grained (10 nm) microstructures suggestive of dynamic recrystallization were also observed in the coatings. Frictional heating during sliding is assessed. The possibility of low temperature recrystallization is discussed in the light of the known resistance of monazite to radiation damage. The ability of La-Monazite to undergo plastic deformation relatively easily at low temperatures may be enabling for its use as a composite interface.

Davis, J. B.↗

NASA NTRS2013

Nonlinear Dynamic Behavior of Impact Damage in a Composite Skin-Stiffener Structure

One of the key issues in composite structures for aircraft applications is the early identification of damage. Often, service induced damage does not involve visible plastic deformation, but internal matrix related damage, like delaminations. A wide range of technologies, comprising global vibration and local wave propagation methods can be employed for health monitoring purposes. Traditional low frequency modal analysis based methods are linear methods. The effectiveness of these methods is often limited since they rely on a stationary and linear approximation of the system. The nonlinear interaction between a low frequency wave field and a local impact induced skin-stiffener failure is experimentally demonstrated in this paper. The different mechanisms that are responsible for the nonlinearities (opening, closing and contact) of the distorted harmonic waveforms are separated with the help of phase portraits. A basic analytical model is employed to support the observations.

Ooijevaar, T. H.↗

NASA NTRS1983

On the solution of elastic-plastic static and dynamic postbuckling collapse of general structure

Many investigations have considered structural collapse from strictly the transient point of view. While such an approach is ideally correct, certain difficulties have to be overcome in its implementation. The present investigation is concerned with the development of self-adaptive algorithms which make it possible to conduct the analysis of both static elastic and elastic-plastic postbuckling, as well as static loading to the onset of buckling followed by subsequent dynamic postbuckling. The approach employed to solve the static portion of loading is to extend the constrained Incremental Newton-Raphson (INR) algorithm by incorporating elastic-plastic constitutive characterizations. Large deformation moderate strain theory is adopted to establish the overall strategy. Attention is given to governing field equations, aspects of algorithmic development, and numerical experiments conducted to illustrate the efficiency and stability of the developed schemes.

Padovan, J.↗

NASA NTRS2006

Simulations of Sea-Ice Dynamics Using the Material-Point Method

In recent years, the availability of large volumes of recorded ice motion derived from high-resolution SAR data has provided an amazingly detailed look at the deformation of the ice cover. The deformation is dominated by the appearance of linear kinematic features that have been associated with the presence of leads. These remarkable data put us in a position to begin detailed evaluation of current coupled mechanical and thermodynamic models of sea ice. This presentation will describe the material point method (MPM) for solving these model equations. MPM is a numerical method for continuum mechanics that combines the best aspects of Lagrangian and Eulerian discretizations. The material points provide a Lagrangian description of the ice that models convection naturally. Thus, properties such as ice thickness and compactness are computed in a Lagrangian frame and do not suffer from errors associated with Eulerian advection schemes, such as artificial diffusion, dispersion, or oscillations near discontinuities. This desirable property is illustrated by solving transport of ice in uniform, rotational and convergent velocity fields. Moreover, the ice geometry is represented by unconnected material points rather than a grid. This representation facilitates modeling the large deformations observed in the Arctic, as well as localized deformation along leads, and admits a sharp representation of the ice edge. MPM also easily allows the use of any ice constitutive model. The versatility of MPM is demonstrated by using two constitutive models for simulations of wind-driven ice. The first model is a standard viscous-plastic model with two thickness categories. The MPM solution to the viscous-plastic model agrees with previously published results using finite elements. The second model is a new elastic-decohesive model that explicitly represents leads. The model includes a mechanism to initiate leads, and to predict their orientation and width. The elastic-decohesion model can provide similar overall deformation as the viscous-plastic model; however, explicit regions of opening and shear are predicted. Furthermore, the efficiency of MPM with the elastic-decohesive model is competitive with the current best methods for sea ice dynamics. Simulations will also be presented for an area of the Beaufort Sea, where predictions can be validated against satellite observations of the Arctic.

Sulsky, D.↗

NASA NTRS2015

Incorporation of Plasticity and Damage Into an Orthotropic Three-Dimensional Model with Tabulated Input Suitable for Use in Composite Impact Problems

The need for accurate material models to simulate the deformation, damage and failure of polymer matrix composites under impact conditions is becoming critical as these materials are gaining increased usage in the aerospace and automotive industries. While there are several composite material models currently available within commercial transient dynamic finite element codes, several features have been identified as being lacking in the currently available material models that could substantially enhance the predictive capability of the impact simulations. A specific desired feature pertains to the incorporation of both plasticity and damage within the material model. Another desired feature relates to using experimentally based tabulated stress-strain input to define the evolution of plasticity and damage as opposed to specifying discrete input properties (such as modulus and strength) and employing analytical functions to track the response of the material. To begin to address these needs, a combined plasticity and damage model suitable for use with both solid and shell elements is being developed for implementation within the commercial code LS-DYNA. The plasticity model is based on extending the Tsai-Wu composite failure model into a strain-hardening based orthotropic plasticity model with a non-associative flow rule. The evolution of the yield surface is determined based on tabulated stress-strain curves in the various normal and shear directions and is tracked using the effective plastic strain. The effective plastic strain is computed by using the non-associative flow rule in combination with appropriate numerical methods. To compute the evolution of damage, a strain equivalent semi-coupled formulation is used, in which a load in one direction results in a stiffness reduction in multiple coordinate directions. A specific laminated composite is examined to demonstrate the process of characterizing and analyzing the response of a composite using the developed model.

Impact↗

NASA NTRS2015

Incorporation of Plasticity and Damage Into an Orthotropic Three-Dimensional Model with Tabulated Input Suitable for Use in Composite Impact Problems

Impact↗

NASA NTRS1975

Dynamic SEM wear studies of tungsten carbide cermets

Dynamic friction and wear experiments were conducted in a scanning electron microscope. The wear behavior of pure tungsten carbide and composite with 6 and 15 weight percent cobalt binder was examined. Etching of the binder was done to selectively determine the role of the binder in the wear process. Dynamic experiments were conducted as the WC and bonded WC cermet surfaces were transversed by a 50 micron radiused diamond stylus. These studies show that the predominant wear process in WC is fracture initiated by plastic deformation. The wear of the etched cermets is similar to pure WC. The presence of the cobalt binder reduces both friction and wear. The cementing action of the cobalt reduces granular separation and promotes a dense polished layer because of its low shear strength film-forming properties. The wear debris generated from unetched surface is approximately the same composition as the bulk.

Brainard, W. A.↗

NASA NTRS1982

Operator split methods in the numerical solution of the finite deformation elastoplastic dynamic problem

The spatial formulation of the elastoplastic dynamic problem for finite deformations is considered. A thermodynamic argument leads to an additive decomposition of the spatial rate of deformation tensor and allows an operator split of the evolutionary equations of the problem into elastic and plastic parts. This operator split is taken as the basis for the definition of a global product algorithm. In the context of finite element discretization the product algorithm entails, for every time step, the solution of a nonlinear elastodynamic problem followed by the application of plastic algorithms that operate on the stresses and internal variables at the integration points and bring in the plastic constitutive equations. Suitable plastic algorithms are discussed for the cases of perfect and hardening plasticity and viscoplasticity. The proposed formalism does not depend on any notion of smoothness of the yield surface and is applicable to arbitrary convex elastic regions, with or without corners. The stabiity properties of the global product algorithm are shown to be identical to those of the algorithm used for the integration of the nonlinear elastodynamic problem. Numerical examples illustrate the accuracy of the method.

Pinsky, P. M.↗

NASA NTRS2009

A Continuum-Atomistic Analysis of Transgranular Crack Propagation in Aluminum

A concurrent multiscale modeling methodology that embeds a molecular dynamics (MD) region within a finite element (FEM) domain is used to study plastic processes at a crack tip in a single crystal of aluminum. The case of mode I loading is studied. A transition from deformation twinning to full dislocation emission from the crack tip is found when the crack plane is rotated around the [111] crystallographic axis. When the crack plane normal coincides with the [112] twinning direction, the crack propagates through a twinning mechanism. When the crack plane normal coincides with the [011] slip direction, the crack propagates through the emission of full dislocations. In intermediate orientations, a transition from full dislocation emission to twinning is found to occur with an increase in the stress intensity at the crack tip. This finding confirms the suggestion that the very high strain rates, inherently present in MD simulations, which produce higher stress intensities at the crack tip, over-predict the tendency for deformation twinning compared to experiments. The present study, therefore, aims to develop a more realistic and accurate predictive modeling of fracture processes.

Yamakov, V.↗

NASA NTRS1969

Hydrodynamics of a new concept of primary containment by energy absorption

Fluid dynamical analysis for idealized reactors system with spherical symmetry determines the effect which the destructive component of a nuclear accident produces on primary containment structures. Steel strands surrounding the reactor cavity in the biological shield exhibit plastic deformation to achieve the energy absorption.

Fistedis, S. H.↗

NASA NTRS1975

Dynamic SEM wear studies of tungsten carbide cermets

Dynamic friction and wear experiments were conducted in a scanning electron microscope. The wear behavior of pure tungsten carbide and composite with 6 and 15 weight percent cobalt binder was examined, and etching of the binder was done to selectively determine the role of the binder in the wear process. Dynamic experiments were conducted as the tungsten carbide (WC) and bonded WC cermet surfaces were transversed by a 50 micron radiused diamond stylus. These studies show that the predominant wear process in WC is fracture initiated by plastic deformation, and the wear of the etched cermets is similar to pure WC. The presence of the cobalt binder reduces both friction and wear. The cementing action of the cobalt reduces granular separation, and promotes a dense polished layer because of its low shear strength film-forming properties. The wear debris generated from unetched surface is approximately the same composition as the bulk.

Brainard, W. A.↗

NASA NTRSDate not supplied

Lessons Learned and Best Practices for Utilizing a Generalized Composite Impact Model

A material model which incorporates several key capabilities which have been identified as lacking in currently available composite impact models has been developed. The material model utilizes experimentally based tabulated input to define the evolution of plasticity and damage as opposed to specifying discrete input parameters (such as modulus and strength). It has been implemented into the commercially available transient dynamic finite element code LS-DYNA® as MAT_213. The model can simulate the nonlinear deformation, damage and failure that take place in a composite under dynamic loading conditions. As MAT_213 is now being used by a general user community that did not participate in the model development process, a number of issues have been identified that caused uncertainty in assembling a MAT_213 input deck and conducting a MAT_213 analysis. The overall goal of this effort is to develop a quantified set of lessons learned and best practices which will permit a new user to conduct useful MAT_213 simulations without needing to have detailed expert knowledge of the material model and its theoretical underpinnings.

Micromechanics↗

NASA NTRS2021

Application of a Developmental Composite Material Model to Predict the Crush Response of Two Energy Absorbers

In 2012, a consortium was formed with the goal of creating a new composite material model capable of predicting the wide range of properties, accumulated damage behavior, and the many different types of failure in composites under impact loading. The material model was developed for execution in the commercially available nonlinear, explicit transient dynamic finite element code, LS-DYNA®. This material model incorporates three sub-models: deformation, damage, and failure. In addition, the model accounts for strain rate and temperature effects and relies heavily on the input of tabulated material response data. The model is designated *MAT_COMPOSITE_TABULATED_PLASTICITY_DAMAGE, or *MAT_213. Initially, *MAT_213 was developed for use with solid elements only; however, a thin shell element formulation for *MAT_213 has been adapted recently. The objective of this project was to find a suitable modeling example to investigate the capabilities and performance of *MAT_213. In 2012, two composite energy absorbers were designed and evaluated at NASA Langley Research Center through multi-level testing and simulation. The first was a conical-shaped energy absorber, designated the conusoid, which consisted of four layers of hybrid carbon-Kevlar® plain-weave fabric oriented at [+45°/-45°/-45°/+45°] with respect to the vertical direction. The second was a sinusoidal-shaped energy absorber, designated the sinusoid, which consisted of hybrid carbon-Kevlar® plain-weave fabric face sheets, two layers for each face sheet oriented at ±45° with respect to the vertical direction, and a closed-cell ELFOAM® P200 polyisocyanurate foam core. Finite element models were developed of the energy absorbers and simulations were performed using LS-DYNA®. In this paper, the development of a *MAT_213 model of a hybrid carbon-Kevlar® plain-weave fabric is presented. Next, comparisons with material characterization tests are presented. Then, test-analysis results are documented for each energy absorber as comparisons of time-history responses, as well as predicted and experimental structural deformations and progressive damage under impact loading using the *MAT_213 material model. Since a prior *MAT_58, or *MAT_LAMINATED_COMPOSITE_FABRIC material model was used in previous simulations of the energy absorbers, comparisons are made between *MAT_58 and *MAT_213 model predictions with test data. Finally, the paper includes a comprehensive list of “lessons learned,” in which a series of parametric studies are documented that were performed to investigate specific issues related to the material model. These “lessons learned” are included in hopes that they may help future *MAT_213 users.

crashworthiness, LS-DYNA transient dynamic simulat↗

NASA NTRS2017

Incorporation of Failure Into an Orthotropic Three-Dimensional Model with Tabulated Input Suitable for Use in Composite Impact Problems

The need for accurate material models to simulate the deformation, damage and failure of polymer matrix composites under impact conditions is becoming critical as these materials are gaining increased use in the aerospace and automotive communities. The aerospace community has identified several key capabilities which are currently lacking in the available material models in commercial transient dynamic finite element codes. To attempt to improve the predictive capability of composite impact simulations, a next generation material model is being developed for incorporation within the commercial transient dynamic finite element code LS-DYNA. The material model, which incorporates plasticity, damage and failure, utilizes experimentally based tabulated input to define the evolution of plasticity and damage and the initiation of failure as opposed to specifying discrete input parameters such as modulus and strength. The plasticity portion of the orthotropic, three-dimensional, macroscopic composite constitutive model is based on an extension of the Tsai-Wu composite failure model into a generalized yield function with a non-associative flow rule. For the damage model, a strain equivalent formulation is used to allow for the uncoupling of the deformation and damage analyses. In the damage model, a semi-coupled approach is employed where the overall damage in a particular coordinate direction is assumed to be a multiplicative combination of the damage in that direction resulting from the applied loads in various coordinate directions. For the failure model, a tabulated approach is utilized in which a stress or strain based invariant is defined as a function of the location of the current stress state in stress space to define the initiation of failure. Failure surfaces can be defined with any arbitrary shape, unlike traditional failure models where the mathematical functions used to define the failure surface impose a specific shape on the failure surface. In the current paper, the complete development of the failure model is described and the generation of a tabulated failure surface for a representative composite material is discussed.

Impact↗

NASA NTRS2017

Implementation of a Tabulated Failure Model Into a Generalized Composite Material Model Suitable for Use in Impact Problems

The need for accurate material models to simulate the deformation, damage and failure of polymer matrix composites under impact conditions is becoming critical as these materials are gaining increased use in the aerospace and automotive communities. The aerospace community has identified several key capabilities which are currently lacking in the available material models in commercial transient dynamic finite element codes. To attempt to improve the predictive capability of composite impact simulations, a next generation material model is being developed for incorporation within the commercial transient dynamic finite element code LS-DYNA. The material model, which incorporates plasticity, damage and failure, utilizes experimentally based tabulated input to define the evolution of plasticity and damage and the initiation of failure as opposed to specifying discrete input parameters such as modulus and strength. The plasticity portion of the orthotropic, three-dimensional, macroscopic composite constitutive model is based on an extension of the Tsai-Wu composite failure model into a generalized yield function with a non-associative flow rule. For the damage model, a strain equivalent formulation is used to allow for the uncoupling of the deformation and damage analyses. For the failure model, a tabulated approach is utilized in which a stress or strain based invariant is defined as a function of the location of the current stress state in stress space to define the initiation of failure. Failure surfaces can be defined with any arbitrary shape, unlike traditional failure models where the mathematical functions used to define the failure surface impose a specific shape on the failure surface. In the current paper, the complete development of the failure model is described and the generation of a tabulated failure surface for a representative composite material is discussed.

polymer matrix composites↗

NASA NTRS1984

Thermal and thermomechanical effects in dry sliding

Developments in the study of interrelated thermal and mechanical phenomena in sliding systems are reviewed. The topics reviewed include mechanisms of frictional heating and the distribution of heat during sliding friction, the experimental measurement and analysis of surface and near-surface temperatures resulting from frictional heating, thermal deformation around sliding contacts and the changes in contact geometry caused by thermal deformation and thermoelastic instability, and the thermomechanical stress distribution around the frictionally heated and thermally deformed contact spots. The influence of the thermal and thermomechanical contact phenomena on friction and wear, surface melting, softening, chemical deterioration, and thermocracking are discussed. The phenomena have important implications in the design and application of sliding or sliding-rolling mechanical components such as dynamic seals, brakes, clutches, plastic bearings, solid or boundary-lubricated bearings, and gears.

Kennedy, F. E., Jr.↗