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At least 19 records

Verification and Validation Process for Progressive Damage and Failure Analysis Methods in the NASA Advanced Composites Consortium

The Advanced Composites Consortium is a US Government/Industry partnership supporting technologies to enable timeline and cost reduction in the development of certified composite aerospace structures. A key component of the consortium's approach is the development and validation of improved progressive damage and failure analysis methods for composite structures. These methods will enable increased use of simulations in design trade studies and detailed design development, and thereby enable more targeted physical test programs to validate designs. To accomplish this goal with confidence, a rigorous verification and validation process was developed. The process was used to evaluate analysis methods and associated implementation requirements to ensure calculation accuracy and to gage predictability for composite failure modes of interest. This paper introduces the verification and validation process developed by the consortium during the Phase I effort of the Advanced Composites Project. Specific structural failure modes of interest are first identified, and a subset of standard composite test articles are proposed to interrogate a progressive damage analysis method's ability to predict each failure mode of interest. Test articles are designed to capture the underlying composite material constitutive response as well as the interaction of failure modes representing typical failure patterns observed in aerospace structures.

Wanthal, Steven↗

An Overview of the NASA Advanced Composites Consortium High Energy Dynamic Impact Phase II Technical Path

Advanced composite structures are increasingly becoming the norm for use in military and commercial aircraft. Many of these structures are in places that are prone to high energy dynamic impact (HEDI) such as a wing or fuselage structures subjected to bird strike or a fan blade out event. Certification testing is expensive and industry currently lacks to the tools to perform reliable certification by analysis or smarter testing. As such, the NASA Advanced Composites Consortium HEDI team was formed with representatives from aerospace original equipment manufacturers, government research laboratories, and academia to advance the state-of-the-art in emerging progressive damage and failure analysis (PDFA) methods in a two phase program. These PDFA approaches have the ability to predict ply-by-ply level damage in composite structures, but to date, have not been thoroughly vetted for HEDI events. In this paper, the technical path that is used in Phase II of the program is presented.

Justusson, Brian↗

Determination of Ballistic Limit for IM7/8552 Using Peridynamics

Significant testing is required to design and certify primary aircraft structure subject to High Energy Dynamic Impact (HEDI) events; current work under the NASA Advanced Composites Consortium (ACC) HEDI Project seeks to determine the state-of-the-art of dynamic fracture simulations for composite structures in these events. This paper discusses one of four Progressive Damage Analysis (PDA) methods selected for this project: peridynamics, through EMU implementation. A brief discussion of peridynamic theory is provided, followed by an outline of ballistic impact testing performed for model development and assessment. Detailed modeling approach and test-analysis correlation for a single open test case are presented, followed by the results of a series of blind predictions made prior to testing and test-analysis correlation performed with measured NASA test results. Specifically, we present simulation results for the ballistic limit (V50) of IM7/8552 composite panels ballistically tested with an impactor representative of a high-velocity fan-blade-out condition. In particular, force and displacement history and the damage state determined analytically are compared to measured results. Ultimately, peridynamics has the ability to predict damage patterns, impact force and deflections during a high energy dynamic impact event on composite panels of different layups using two different types of impactors. Blind predictions were promising and increased confidence in the model for impact simulation. There are open questions regarding the fidelity of the test fixture idealization in regards to stiffness and damping which will need to be addressed in future work.

Cuenca, Fernando↗

Verification Benchmarks and Validation of MAT261 for High Energy Dynamic Impact Applications

Advanced computational methods for composite structures can enable smarter testing and potentially certification by analysis. These methods, known as progressive damage and failure analysis (PDFA) methods, can predict lamina level mechanics including failure and subsequent propagation. When introduced into a commercial off the shelf finite element solver such as ABAQUS, LS-DYNA, or ANSYS, it enables end users to effectively exercise PDFA methods; however, it requires an understanding of the assumed mechanics and underlying coded response. In this paper, verification benchmarks developed under the NASA Advanced Composite Consortium for a class of PDFA methods known as continuum damage mechanics approaches are applied to the native LS-DYNA material model MAT261. As a result of the verification, an instability was discovered and subsequently corrected with an engineering solution. The results of the preliminary MAT261 simulations for high energy dynamic impact and the engineering solution are compared and a discussion about the significance is presented.

Molitor, Matthew↗

Progressive Damage and Failure Analysis of Bonded Composite Joints at High Energy Dynamic Impacts

Both wing and fuselage structures utilize bonded composite joints for structural efficiency in modern commercial and military aircraft. To ensure compliance with certification requirements mechanical fasteners are typically used as a failsafe mechanism for appropriate strength in the event of complete stiffener disbond. However, the use of fasteners decreases the structural efficiency of the structure by adding weight. This establishes the requirement to better exploit the efficiency of bonded structures and fully understand the failure behavior of adhesively bonded composite structures, particularly when subjected to elevated loading rates due to high energy dynamic impacts (HEDI). For this reason, the NASA Advanced Composite Consortium (ACC) HEDI team developed an experimentation and numerical modeling program for high rate loading of composite joints. In the present work, the response of adhesively bonded composite joints subjected to elevated loading rates is studied numerically and validated against experimental results. Due to dynamic considerations of experiments, the idea of wedge insert was extended to use with Split Hopkinson Pressure Bar (SHPB) testing techniques. Mode-I and Mode-II test configurations were simulated to evaluate the capability of two continuum damage material (CDM) models in LS-DYNA, namely MAT162 and MAT261. Three different levels of fidelity were considered to investigate the level of detail required to numerically predict the failure behavior and the results from high fidelity analysis are presented.

MAT261↗

Design for Manufacturing Tool for Automated Fiber Placement Structures - Verification and Validation

A tool has been developed to address the growing Design for Manufacturing needs for composite structures, specifically those manufactured with automated fiber placement. This manufacturing approach presents unique challenges associated with puckers and wrinkling, tow overlaps and gaps, fiber deviation, and laminate strength. Achieving a satisfactory laminate design usually requires finding compromises between those four areas. The developed tool, dubbed the Central Optimizer, assists with the process of balancing competing design metrics in automated fiber placement. This tool was developed under the NASA Advanced Composites Consortium with input from industry partners. Under this program, the Central Optimizer has been exercised on three different structures to verify its functionality and validate ability to improve the design process for automated fiber placement structures.

August T Noevere↗

Unified Analysis of Aerospace Structures through Implementation of Rapid Tools into a Stress Framework

Rapid structural analysis tools have become an important part of the design cycle for aerospace companies for the last several decades. As these tools have been developed over time, there is often little consideration for shared software infrastructure between the tools, which makes design and analysis cumbersome due to a lack of commonality in input and output data and reporting, as well as poor traceability of results. Under the Rapid Tools task of the Advanced Composites Consortium (ACC), four aerospace tools were recently implemented or enhanced in the HyperSizer stress framework and then evaluated by this consortium of industry and government organizations. The framework provides an automated software environment for executing the rapid tools for analysis and sizing, quantifying margins of safety for thousands of load cases, and generating reports in support of FAA certification. This paper describes the process by which the tools were enhanced or implemented in the stress framework under the ACC project, and the evaluation conducted by industry consortium members.

Craig S Collier↗

TPSAS-NF1676L-32030-DND

Composite structures are often difficult to inspect due to the anisotropic nature of the material systems and the range of flaws and defects that can arise in the manufacturing process. NASA?s Advanced Composites Project, a public-private partnership between government, universities and industry, seeks to address improved methods, tools, and protocols to reduce the development and certification timeline for composite materials and structures. The rapid inspection of composites is one of the three focused research areas of the project. One deliverable of the project is to develop an NDE Methods and Capabilities Handbook. This Handbook provides a publically available guidance document that facilitates the selection of appropriate NDE techniques and provides recommended protocols for detecting and characterizing common flaw types in solid laminate polymer matrix composite (PMC) structures. The Handbook will reduce the time required to develop qualified inspection processes for composite aircraft structures during the development, certification, and manufacturing phases by providing a reference that helps minimize trial and error and provides guidance on best practices, techniques, and settings, for specific flaw types and geometries. The Handbook will include an NDE Guidance Matrix that provides an applicability rating for NDE techniques as they apply to given flaw types. NDE techniques will include, but is not limited to ultrasound, laser based ultrasound, infrared thermography, and x-ray CT. Flaw types will include, but are not limited to porosity, delamination, voids, AFP defects and impact damage. The Handbook will contain details that support the applicability rating including, but not limited to, specimen details, inspection parameters, data analysis techniques, inspection efficiency (speed & cost), and limitations. This presentation will describe key Handbook activities with examples of the techniques and flaw types examined by the Advanced Composite Consortium members.

Patricia A Howell↗

NDE Methods and Capabilities Handbook – Resources for the Composites NDE Community

Composite structures are often difficult to inspect due to the anisotropic nature of the material systems and the range of flaws and defects that can arise in the manufacturing process. NASA’s Advanced Composites Project, a public-private partnership between government, universities and industry, sought to address improved methods, tools, and protocols to reduce the development and certification timeline for composite materials and structures. The rapid inspection of composites was one of the three focused research areas of the project. One deliverable of the project was to develop an NDE Methods and Capabilities Handbook. This Handbook provides a publicly available guidance document that facilitates the selection of appropriate NDE techniques and provides recommended protocols for detecting and characterizing common flaw types in solid laminate carbon fiber reinforced polymer composite (CFRP) structures. The Handbook seeks to reduce the time required to develop qualified inspection processes for composite aircraft structures during the development, certification, and manufacturing phases by providing a reference that helps minimize trial and error and provides guidance on best practices, techniques, and settings, for specific flaw types and geometries. NDE techniques include, but are not limited to ultrasound, laser based ultrasound, infrared thermography, and x-ray CT. Flaw types include, but are not limited to porosity, delamination, voids, AFP defects and impact damage. The Handbook contains details such as inspection parameters, data analysis techniques, inspection efficiency (speed & cost), and limitations. This presentation will describe key Handbook activities with examples of the techniques and flaw types examined by the Advanced Composite Consortium members. Availability of the fabricated NDE standards as well as the raw data collected on the standards by the Consortium members to the NDE community is discussed.

Patricia A Howell↗

Improved Benchmarking of Cohesive Elements in Abaqus Standard for Predicting Disbond and Delamination in Composite Structures

Traditional approaches for aircraft certification require the assumption of an initial flaw condition, either represented as barely visible impact damage (BVID) or through inclusion of a Teflon insert to serve as surrogate damage. Based on the initial composite damage state, the structure must be shown to demonstrate structural durability and damage tolerance (DaDT) according to the following criteria: a. Damage displays no detrimental growth under cyclic loading b. The structure is able to sustain design limit load (DLL) Currently, the only available manner for validating structural performance is through test. Since damage can occur over a wide variety of areas within a structure, this approach has proven to be increasingly expensive and time consuming for composite airframes and acreage structure within the design-test-certification building block. A further complicating factor is the requirement to accurately capture the most critical damage morphologies as a starting condition. To understand the severity of the damage, it is either required to experimentally determine the most critical areas at tremendous expense or rely on legacy data of similar structural testing, which limits design space expansion. A preferred solution is to use advanced analysis to provide improved understanding of load margins for critical locations based on a wide variety of potential starting damage conditions. The standard industry approach for DaDT certification adheres to the use of the traditional virtual crack closure technique (VCCT) method. VCCT is generally a preferred method because it conforms to the current certification principles of damage from a known flaw, and when used correctly, can be effective at predicting delamination propagation under static and cyclic loading. The VCCT method requires the inclusion of an initial flaw in the finite element (FE) model requiring a-priori knowledge of the flaw location. This in turn requires a plethora of analysis cases to be examined to cover a reasonable span of potential damage states. Additionally, the VCCT approach requires node-to-node connectivity rendering it incompatible with the best practices and approaches for using continuum damage mechanics (CDM) based progressive damage and failure analysis (PDFA) tools within a typical FE solver. Alternatives to VCCT have emerged in the form of cohesive elements which utilize the cohesive zone model (CZM). Unlike VCCT which models linear elastic fracture mechanics, cohesive elements couples continuum and fracture based responses through the use of bilinear traction separation laws. These laws are defined based on a penalty stiffness, a cohesive strength, and a strain energy release rate. The approach can be mesh regularized with native cohesive elements within many FE solvers such as Abaqus and LS-DYNA. In Phase I of the NASA Advanced Composites Consortium (ACC) post-buckled stiffened panel with BVID, Strength and Life [1], the performance of cohesive elements were benchmarked in comparison to VCCT and LEFM solutions and showed good agreement using Abaqus explicit [2]. To realize savings on current and future programs, it is still necessary to close technical gaps related to the use of cohesive elements with Abaqus Standard. Within a program environment, standard finite element analysis is the preferred analytical capability for quasi-static loading as it eliminates uncertainty due to oscillatory behavior commonly seen with explicit analysis. This oscillatory behavior creates difficulties in writing margins of safety based on the analysis. The use of negative tangent stiffness material models complicates convergence which typically requires the use of numerical controls such as viscous damping to overcome. To date, there has not been a comprehensive study on how to establish best practices for cohesive element convergence for predictive capability within the Abaqus implicit solver. In pursuit of these goals, under the NASA ACC program, several numerical benchmark problems were proposed including pure mode I (double cantilevered beam – DCB), pure mode II (end notch flexure – ENF), and symmetric/unsymmetric evolving mixed mode (single leg bend – SLB). This paper focuses on the use of cohesive elements to model the delamination through the use of CZM. Specifically, finite element models for the DCB, ENF, symmetric SLB, and unsymmetric SLB, are developed and various solution controls for convergence are studied to develop a best practice. Once the best practice has been developed, the predictive capability of the objective CZM model is used to analyze the hat pull-off strength of a standard hat stiffened configuration under various loading conditions.

Abaqus↗

NASA Advanced Composites Project

The recently-completed NASA Advanced Composites Project (ACP) successfully developed several new technologies aimed at reducing the timeline to design and certify composite aircraft structures. Advancements in the areas of manufacturing simulation, nondestructive inspection and advanced structural design and analysis methodologies were completed in late 2019 under the Advanced Composites Consortium (ACC) public/private partnership as well as NRA-funded university contracts. In the area of Structures, the ACC made significant improvements in rapid design tools for preliminary sizing of structure, along with developing detailed static and fatigue strength prediction methods and methods for modeling high energy impact events in composite structures. These new methodologies and toolsets were validated against a range of representative test data using a comprehensive verification and validation approach which has been published and is now used extensively on other programs. Specific new tool improvements supported by ACC include NASA’s CompDam code and Floating Node Method code. CompDam is now available from NASA as open source code. The team alsoworked on improved impact modeling using LS-Dyna™ and improved delamination modeling using Abaqus™. Rapid design tool improvements are available through Hypersizer. The ACC team released well over 50 publications documenting these method improvements, and the ACP recently received the prestigious NASA Group Achievement Award for their work.Typical Hat Stiffened Panel Test Article Used for Method Validation

ACC↗

NDE Methods and Capabilities Handbook - Resources for the Composites NDE Community

Composite structures are often difficult to inspect due to the anisotropic nature of the material systems and the range of flaws and defects that can arise in the manufacturing process. NASA’s Advanced Composites Project, a public-private partnership between government, universities and industry, sought to address improved methods, tools, and protocols to reduce the development and certification timeline for composite materials and structures. The rapid inspection of composites was one of the three focused research areas of the project. One deliverable of the project was to develop an NDE Methods and Capabilities Handbook. This Handbook provides a publicly available guidance document that facilitates the selection of appropriate NDE techniques and provides recommended protocols for detecting and characterizing common flaw types in solid laminate carbon fiber reinforced polymer composite (CFRP) structures. The Handbook seeks to reduce the time required to develop qualified inspection processes for composite aircraft structures during the development, certification, and manufacturing phases by providing a reference that helps minimize trial and error and provides guidance on best practices, techniques, and settings, for specific flaw types and geometries. Techniques include, but are not limited to ultrasound, laser based ultrasound, infrared thermography, and x-ray CT. Flaw types include, but are not limited to porosity, delaminations, voids, Automated Fiber Placement (AFP) defects and impact damage. The Handbook contains details such as inspection parameters, data analysis techniques, inspection efficiency and limitations. This presentation will describe key Handbook activities with examples of the techniques and flaw types examined by the Advanced Composite Consortium members. Availability to the NDE community of the fabricated NDE standards as well as the raw data collected on the standards by the Consortium members is discussed.

Nondestructive Evaluation↗

NDE Methods and Capabilities Handbook - Resources for the Composites NDE Community

Composite structures are often difficult to inspect due to the anisotropic nature of the material systems and the range of flaws and defects that can arise in the manufacturing process. NASA’s Advanced Composites Project, a public-private partnership between government, universities and industry, sought to address improved methods, tools, and protocols to reduce the development and certification timeline for composite materials and structures. The rapid inspection of composites was one of the three focused research areas of the project. One deliverable of the project was to develop an NDE Methods and Capabilities Handbook. This Handbook provides a publicly available guidance document that facilitates the selection of appropriate NDE techniques and provides recommended protocols for detecting and characterizing common flaw types in solid laminate carbon fiber reinforced polymer composite (CFRP) structures. The Handbook seeks to reduce the time required to develop qualified inspection processes for composite aircraft structures during the development, certification, and manufacturing phases by providing a reference that helps minimize trial and error and provides guidance on best practices, techniques, and settings, for specific flaw types and geometries. Techniques include, but are not limited to ultrasound, laser based ultrasound, infrared thermography, and x-ray CT. Flaw types include, but are not limited to porosity, delaminations, voids, Automated Fiber Placement (AFP) defects and impact damage. The Handbook contains details such as inspection parameters, data analysis techniques, inspection efficiency and limitations. This paper describes key Handbook activities with examples of the techniques and flaw types examined by the Advanced Composite Consortium members. Availability to the NDE community of the fabricated NDE standards as well as the raw data collected on the standards by the Consortium members is discussed.

nondestructive evaluation↗

Integration of Structural Analysis and Manufacturing Process Planning for Global Optimization with Automated Fiber Placement

Design of mass-efficient composite structures intended for Automated Fiber Placement (AFP) requires close interaction between structural analysis and manufacturing process planning. Tools exist for each of these disciplines, but software interplay has been insufficient for rapid and efficient design iteration. Within the NASA Advanced Composites Consortium (ACC), the Design for Manufacturing (DFM) task has made significant progress towards linking these disciplines and respective software – HyperX (design), CAPP (process planning), and VCP (tool path generation). The initial focus in previous work was on data exchange between disciplines. The ability to both export and consume composite design and manufacturing data to and from each tool. This paper focuses on the effort to automate and streamline the connection between the tools listed above, with the goal of being able to automatically generate a composite AFP design that is mass-efficient and manufacturable. The optimization method being pursued is a bi-level approach, where each tool performs optimization within its discipline. The optimization in HyperX is focused on mass and laminate strength, while CAPP is focused on maximizing manufacturability. VCP is used to generate fiber paths for each design iteration. These sub-processes are wrapped with a global level optimization, driven by HyperX, used to converge the design. This paper describes the current state of this effort, which is a completed HyperX-VCP iteration loop and initial work on the HyperX-CAPP iteration loop. Additionally, example results are shown for a wind blade structure with double curvature.

Automated Fiber Placement↗

FEA-Based Failure Analysis of Post-Buckled Composite Multi-Hat Stiffened Panel Under Static Compression

The aerospace industry uses composite multi-hat stiffened panels for skins because of their high strength-to-weight and stiffness-to-weight ratios. However, laminated composites with initial flaws are susceptible to delamination under buckling loads. The goal is to ensure damage initiation occurs past the buckled state, only stable damage progression at loads below the ultimate compressive load, and debonding failure past the ultimate compressive load. This approach reduces weight and addresses a potential design review for future aircraft repairs. The need exists to better understand damage initiation and growth mechanisms in composite structures while assisting in the design, analysis, and sustainment methods. Teflon inserts simulate damage defects during manufacturing, while barely visible impact helps capture human error during manufacturing. This work shows the interaction between the skin-stringer and ply-ply separations at the post-buckled state for both defect events using Abaqus Virtual Crack Closure Technique (VCCT). The initial configuration for the Teflon case was to leave the Teflon region unbonded, and the initial impact damage region approximation came from the experimental data and was considered the initial configuration. When compared against the experimental data produced through the NASA Advanced Composites Project (ACP), the present model captured damage transition from skin-hat to ply1-ply2. The model validations were within ~5% of the experimental data.

composite↗