AE 569 - FALL 2012 PROJECT FOR GRADUATE STUDENTS (due January 26th Saturday- if not finished by Jan.

26, you can use incomplete time till February 2 nd 2013) FINITE ELEMENT ANALYSIS BASED PROGRESSIVE FAILURE ANALYSIS OF LAMINATED COMPOSITE STRUCTURES 1. INTRODUCTION AND GENERAL DESCRIPTION OF THE FINITE ELEMENT BASED PROGRESSIVE FAILURE ANALYSIS In this project groups (2 student per group) are expected to perform progressive failure analysis of a composite laminate with a central hole by finite element analysis. Students are expected to use a commercial finite element program as a solver, and write a code which will perform failure analysis and progress failure by employing sudden material property degradation using load controlled numerical test. Students should not use the progressive failure analysis modules of certain commercial codes such as Abaqus, MSC Nastran 2012 etc. The idea is to write a progressive failure analysis code and employ a commercial finite element code as a solver. This way, failure analysis code can be expanded by employing different failure theories. Two flowcharts of the progressive failure analysis were discussed in class. Flowcharts are linked in the course web site. These flowcharts are specific for hand calculation. In this project, finite element based progressive failure analysis will be performed by editing the input file of the finite element code which includes all the model information. This process is summarized below in Fig.1. Prepare the FE model and input file (including the load) Carry out FE solution and determine layer stresses/strains. FE code has to executed externally from the main code that you will write Read the output file of the FE code (specifically read layer stresses and strains depending the on the failure criterion used) Determine the failure indices inside your code (of the particular failure criterion)

If no failure of any ply is predicted, increment the load by editing the input file of the FE code.

Check if any ply fails or not

If failure of any ply is predicted, employ the material property degradation scheme and degrade the material property of the ply material. This will be done by editing the input file. Do not increment load.

Check ultimate failure and stop accordingly or stop when a particular load level is reached.

Fig. 1 Simplified flowchart of finite element analysis based progressive failure analysis

NOTE: Students who find it hard to fully automate the failure progression, via an external code, which does everything (runs FE code, reads output file, calculates failure indices based on the failure criterion used, performs material property degradation and modifes the input file), can have a separate code calculating failure indices and execute FE runs separately. This way, the process will not be automatic, and the user has to intervene at every step of the failure progression. In order to effectively allow material property degradation at the ply level, for each element in the finite element mesh distinct composite laminate properties with distinct two dimensional orthotropic materials has to be generated. Stiffness reduction scheme can then be implemented easily for the failed ply by referencing the element property identification and material identification numbers of the ply. A typical input file (.bdf) of Nastran is shown below. In this file PCOMP refers to the composite property identification cards. In order to progress failure at the ply level, distinct composite property identification has to be assigned for each element. These are given by the red numbers in the PCOMP cards. The blue numbers in the PCOMP cards refer to the layer materials. Thus, for each layer we define a new material. CQUAD4 cards refer to elements. The green numbers, in the CQUAD4 cards, refer to the element numbers and the red numbers in the CQUAD4 cards refer to the composite property cards PCOMP. MAT8 cards define the 2D orthotropic materials. Thus, in the example .bdf file given below, we have N*L number of layer materials defined (L: # of layers in an element, N: # of elements in the model). During material property degradation, all we have to identify is the number of the MAT8 cards that we should modify depending on whether failure is predicted or not. Once the related MAT8 card is modified, composite properties (PCOMP cards) will be automatically updated since PCOMP cards reference material MAT8 cards, as indicated by the blue numbers shown in the PCOMP cards. (Note that for ease of explanation, this input file is edited and brought into the form shown below) An example output file is given after the input file. In this example, it is assumed that laminate has two plies. After the output file is created (following a Nastran run), the lines giving the stress results should be read. While reading the lines, element IDs and ply IDs should also be read and recorded. If failure of any particular layer is predicted, element ID and ply ID will be used to find the ID number of the MAT8 cards. Once the IDs of the failed plies are identified, these MAT8 cards should be modified in the input file. After the modification of the MAT8 cards, the code has to call for another FE run and the whole process will start all over again. NOTE: Students who want to use other FE codes such as Abaqus, Ansys can do so. In that case, they have to use the input and output files of those programs, and carry out the reading and editing operations accordingly. The main code that will perform progessive failure analysis can be written in FORTRAN, PYTHON, PERL (Ansys uses this script language), MATLAB, VISUAL BASIC etc. Remember that you have to read and edit text files many times during the progressive failure analysis. Therefore, you should use the code that you are most comfortable with.

----------------------------------------------------------------------------------------------------------------EXAMPLE INPUT FILE OF NASTRAN RED: PCOMP PROPERTY NUMBERS-PCOMP NO. BLUE: LAYER MATERIAL NUMBERS - MID MO. and MAT8 numbers GREEN: ELEMENT NUMBERS - CQUAD4 NO. $ NASTRAN input file created by the MSC MSC.Nastran input file $ translator ( MSC.Patran 13.1.116 ) on October 24, 2009 at 11:13:35. $ $ Direct Text Input for Bulk Data $ Elements and Element Properties for region : shell $ Composite Property Record created from P3/PATRAN composite material $ record : lam $ Composite Material Description : PCOMP 1 50. TSAI 0. 0. 1 .25 0. YES 2 .25 10. YES 3 .25 20. YES . . . . . . . . . . . . . . . L .25 20. YES PCOMP 2 50. TSAI 0. 0. L+1 .25 0. YES L+2 .25 10. YES L+3 .25 20. YES . . . . . . . . . . 2L .25 20. YES . . . . . . . . . . PCOMP N 50. TSAI 0. 0. (N-1)L+1 .25 0. YES (N-1)L+2 .25 20. YES NL $ $ CQUAD4 CQUAD4 CQUAD4 . . . . . . CQUAD4 .25 1 2 3 . . . N N 1 2 3 40. 1 2 3 . . . 71 2 3 4 . . . 72 YES 11 12 13 . . . 81 1 10 11 12 . . . 80 .25 0. 0. 0. . . . 0. . . . 50. YES

$ Referenced Material Records $ Material Record : ortho $ Description of Material : Date: 27-Dec-08

Time: 16:36:32

MAT8 MAT8

181000. 10300. .28 7170. 7170. 5000. 1.6-9 1500. 1500. 40. 246. 68.

-.5 2 181000. 10300. .28 7170. 7170. 5000. 1.6-9 1500. 1500. 40. 246. 68. -.5 MAT8 3 181000. 10300. .28 7170. 7170. 5000. 1.6-9 1500. 1500. 40. 246. 68. -.5 . . . . . . . . . . . . . . . . . . MAT8 N*L 181000. 10300. .28 7170. 7170. 5000. 1.6-9 1500. 1500. 40. 246. 68. -.5 $ Nodes of the Entire Model GRID 1 0. 0. 0. GRID 2 125. 0. 0. GRID 3 250. 0. 0. GRID 4 375. 0. 0. GRID 5 500. 0. 0. GRID 6 625. 0. 0. GRID 7 750. 0. 0. GRID 8 875. 0. 0. GRID 9 1000. 0. 0. GRID 10 0. 125. 0. GRID 11 125. 125. 0. GRID 12 250. 125. 0. GRID 13 375. 125. 0. GRID 14 500. 125. 0. GRID 15 625. 125. 0. GRID 16 750. 125. 0. $ Loads for Load Case : Default $ Displacement Constraints of Load Set : n SPC1 1 123 1 THRU 9 $ Displacement Constraints of Load Set : n1 SPC1 3 3 73 $ Pressure Loads of Load Set : p PLOAD4 1 1 -1.-4 THRU 64 ----------------------------------------------------------------------------------------------------------------EXAMPLE OUTPUT FILE OF NASTRAN
ELEMENT PLY STRESSES IN FIBER AND MATRIX DIRECTIONS ID ID NORMAL-1 NORMAL-2 SHEAR-12 1 1 3.00725E+04 -4.84032E+03 4.64574E+03 1 2 8.26329E+04 7.01767E+02 -8.22791E+03 2 1 3.85178E+04 -1.02513E+04 3.31139E+03 2 2 4.51463E+04 -5.88696E+02 -1.19184E+04 3 1 4.05495E+04 -1.06741E+04 2.74296E+03 3 2 4.54650E+04 -6.57785E+02 -1.21436E+04 . . . . . . . . . . ---------------------------------------------------------------------------

2. MODEL DESCRIPTION The model which will be used in the progressive failure analysis is a square composite laminate with a central hole shown in Fig. 2 below. The material properties of the ply material (fiber: T300/matrix: F934) is given by: E1=148 GPa, E2=9.65 GPa, v12=0.3, G=4.55 GPa Xt=1314 MPa, Xc=1220 MPa, Yt=43 MPa, Yc=168 MPa, S=48 MPa Ply thickness: 0.10 mm Laminate configurations to be investigated: [0/0], [90/90] , [0/90] and [-45/45] NOTE: In order to make a simple model, in this project only two plies per element are used in the laminate.

y, 90o

10 cm

x, 0o

Hole diameter = 3 cm

Fig. 2 Square composite laminate with a central hole Laminates with the central holes will be investigated under uniaxial loading as shown in Fig. 3. Model the uniformly distributed load using CID distributed load option. Section of the input file which gives the nodal forces for a sample distributed load case is given below. In this example a uniformly distributed load of 10 N/m is distributed along an edge which has a length of 0.05m. On the edge there are 3 elements (same length) and four nodes. The corner nodes 14 and 56 take a share of (10*(0.05/3))/2=0.08333 N. The middle nodes 28 and 42 take up 2*(10*(0.05/3))/2=0.16667 N. So, while increasing the loads you need to change the fields which gives the nodal loads which are 0.08333 N in this example.
FORCE FORCE FORCE FORCE FORCE FORCE 1 1 1 1 1 1 14 28 28 42 42 56 .08333331. .08333331. .08333331. .08333331. .08333331. .08333331. 0. 0. 0. 0. 0. 0. 0. 0. 0. 0. 0. 0.

Nx (N/m)

Nx (N/m)

Fig. 3 Uniaxial tensile loading During the finite element analysis, due to symmetry only quarter laminate will be modeled. The model is shown in Fig. 4 for the uniaxial tensile loading. Finite element model has 36 elements and 2 plies per element. Thus, total number of 2D orthotropic materials to be defined, is 72. It is assumed that the tests are carried on a uniaxial test machine. Therefore, boundary conditions are defined accordingly. 1: x disp. , 2: y disp. , 3: z displ. , 4: x-axis rot. , 5: y-axis rot. , 6: z-axis rot. In the project, you are also asked to draw the load displacement curve. For the displacement, you can take the x-displacement of the corner node shown in Fig. 4 to draw the load displacement curve. To draw the load displacement curve, at each step you need to store the value of the distributed load and displacement of the corner node. In some steps load will be same but due to failure of plies, because of material propety degradation, displacement will change. Therefore, to get the full picture of load-displacement history, you need to store the load and displacement values at every step.

1=5=0

3=0

2=4=0

Use the displacement of this node to draw the load displacement curve

Fig. 4 Finite element model for the uniaxial tensile loading

3. FAILURE CRITERIA AND MATERIAL PROPERTY DEGRADATION METHOD Failure Criteria Two dimensional Tsai-Wu failure criteria will be implemented in the progressive failure analysis code. References: Tsai-Wu S.W. Tsai, A General theory of strength for anisotropic materials, Journal of Composite Materials, 5(1), 58-80 (1971). Material Property Degradation Use sudden degradation and a stiffness reduction factor of 0.001. Once failure is predicted, degrade all properties at once. This is the so-called complete ply failure method which is the conservative approach. Degrade E1,E2,G12,G13,G23,v12 by the reduction factor of 0.001. Once a property is degraded, make sure that you do not degrade it again during failure progression or load increase. 4. PROJECT REQUIREMENTS a) For the uniaxial tensile load case, students are expected to determine first ply load, failure progression and ultimate failure load. For failure progression prepare simple plots at intermediate load steps (not all load steps) such as shown below.

Load level: Nx = XXX where the green dot shows that a single layer has failed in that element and that both layers have failed. red dot shows

NOTE: For ultimate failure, all layers of the elements in the FE model along a line must be failed. So, you should have all red dots along a line which breaks the laminate into two such as the one shown in the figure below.

b)

Report first ply and ultimate loads for the four different laminate configurations in tabular form. Comment on the first ply and ultimate failure loads of the four laminates studied. Also for the four different laminates, plot load versus displacement curve. Load and displacement definitions are made in the previous section.

c)

Write an project report which has the following sub-sections: Title page, group members Introduction: Give a brief introduction Description of your code (or your methodology) Verification of your code (present a verification for the no hole case. And compare first ply load with the hand calculation (such as the one done in class) Results: response to project requirements should be given here. Conclusion : Make concluding remarks. Appendix: Give the main code you have written, initial input file of the FE code, and initial (after first run) output file of the FE code HOW TO CALL FOR NASTRAN RUN FROM YOUR CODE

FORTRAN USERS: Students who use Fortran can use the following statements to call Nastran runs inside the Fortran code.
CALL SYSTEM('C:\MSC.Software\MSC.Nastran\bin\mdnast2008.exe agard.bdf')

Note that you have to address the folder where the nastran.exe file resides. The following is another example. For instance, if your nastran.exe is under D drive then address that.

CALL SYSTEM('D:\Users\ERKUT\AppData\Roaming\MSC.Software\MD_Nastran\bin\mdnast20 08.exe agard.bdf')

Important Note: There are two .exe files for Nastran. One ends with w and one does not have w. Do not use mdnast2008w.exe or nastranw.exe (exe files with w ). In that case Fortran code does not wait for the nastran run to complete its execution. Use mdnast2008.exe or nastran.exe. In that case Fortran code waits for the nastran run to complete its execution. MATLAB USERS: You may use the following command. Again use .exe file which does not end with w.
system ('C:\MSC.Software\MSC.Nastran\bin\mdnast2008.exe agard. bdf')