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Composites: Part A
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a r t i c l e i n f o a b s t r a c t
Article history: In an attempt to gain better understanding and predictability of the mechanical behavior of titanium-
Received 20 February 2013 lamella reinforced CFRP bolted joints, an efcient progressive damage model was developed in this work.
Received in revised form 31 July 2013 The model was used to represent bearing effects in a double-lap composite bolted joint subjected to ten-
Accepted 19 September 2013
sile loading. The progressive damage model relies on stress-based failure criteria accounting for three
Available online 2 October 2013
orthogonal fracture planes and a continuous degradation method depending on stress-state and stress
history. It is shown that the model, which for material specication uses available elastic moduli and
Keywords:
strength values, can be rened to reasonable accuracy with regard to experiments through a parameter
A. Polymermatrix composites (PMCs)
A. Hybrid
identication process. For pure CFRP bolted joints, the model predicts accurately both bolt strength and
B. Strength total displacement at nal failure. The predicted strength enhancement, achieved by replacing CFRP lay-
C. Finite element analysis (FEA) ers with titanium sheets, is in good agreement with experimental data obtained from the literature.
2013 Elsevier Ltd. All rights reserved.
1359-835X/$ - see front matter 2013 Elsevier Ltd. All rights reserved.
http://dx.doi.org/10.1016/j.compositesa.2013.09.011
52 G. Kolks, K.I. Tserpes / Composites: Part A 56 (2014) 5163
1 v
u init
u
init tEy Ez
myz mzy 17
Ez Einit
rij y
s
init Ex Einitz
1 1+ i mxz m zx 18
Ez Einit
x
Fig. 4. Variation of degradation variable wij with respect to the damage variable di. in compatibility with Eq. (15).
G. Kolks, K.I. Tserpes / Composites: Part A 56 (2014) 5163 55
4. FE (static) model
Analysis start
Read parameters
Create FE-entities
Set initial
displacement
Increase
displacement value
Apply YES
displacement load
NO Maximum number of
damage iterations per load Degradation
step exceeded?
Solve FE problem
YES
NO
Maximum number of NO Read Evaluate New maximum damage
iterations exceeded? stresses failure criteria variables > 1 detected?
YES
Analysis end
~ex0~
ey0~
ez0 . Fig. 7 provides an overview over the mapped meshing marginal penetration and tensile pressure upon existing gaps are
applied to all of the models parts. allowed (chattering control), convergence behavior can be im-
In favor of control and reproducibility, mapped parametric proved signicantly. In case too little chattering control is dened,
meshing is applied to the entire model. In both pulling strap and convergence may be impeded by abruptly changing contact status
specimen, square shaped areas surrounding the bolt holes, in between successive iterations.
which the transition from polar to rectangular mesh is conducted, The use of the Lagrange multiplier method in the presented
were dened. Washers and bolts were entirely meshed in polar model results in accurate modeling of contact behavior with an
direction resulting in wedge-shaped elements along the bolt sym- acceptable convergence rate. It is applied to all penetration-sensi-
metry axes. tive contact pairs, i.e. those involving the bolt shaft due to their sig-
Meshing of the pulling strap is carried out creating SOLID46 ele- nicance for the joint stiffness, the interface between pulling-strap
ments [17]. These are brick-shaped 8-node element with three and specimen, in case bolt pretension studies are performed, as
translational degrees of freedom each that allow for a representa- well as the bonded contact between layered and non-layered ele-
tion of layered solid structure within one element. Thus, it is a con- ment specimen region. In order to reduce computational costs,
venient way of modeling the global stiffness behavior of plane ANSYS features a contact algorithm that employs Lagrange multi-
layered ber composites. Compared to a layer-wise modeling with pliers in the contact normal and penalty method in the tangent
solid elements, the featured integration in thickness-direction dur- direction. This is implemented instead of the pure Lagrange multi-
ing the composition of the element stiffness matrix reduces the re- plier method, with the exception of the bonded specimen contact.
quired memory and computing costs signicantly. On the contrary, As a measure to further improve the stability of the contact
this element type does not allow layers with bilinear plasticity def- algorithm, initial contact closure is allowed over small gaps and
inition, which is the required material model for titanium layers. penetration. In order to avoid problems arising from discontinuous
The specimen region around the bolt hole, which will face deg- stiffness distribution, the specimen volume is covered by very thin
radation during the analysis, is modeled using one layer of SOLID45 layers of solid elements (see Fig. 8) which are not subjected to deg-
elements [17] per laminate ply. SOLID45 elements share properties radation, but other than that feature the same characteristics as the
with the above mentioned SOLID46 without the ability to repre- next underlying elements. These steady layers transmit the contact
sent multiple layers, yet they feature plasticity models. By model- reaction to the degradation-active elements and are thin enough to
ing each single composite layer, large shear-deformations with a not signicantly redistribute stresses around damaged regions.
component in thickness-direction of single layers can be accounted
for and contact in the boltspecimen interface is represented more 4.3. Constraints and body loads
accurately than is the case with elements that integrate several
layers, due to a close-meshed distribution of nodes on the outer The most direct way of dening load to a model that outputs
surface. With the objective of reducing the total number of degrees nominal bearing stress against displacement is to impose displace-
of freedom, the inactive area of the specimen is modeled with SO- ment. For this purpose, the particular nodes that embody the long
LID46 elements and joined with the active part by bonded contact ends face of the pulling strap have all their degrees of freedom
elements. constrained to zero. The outer specimen face is treated equally, ex-
Bolts and washers are built of SOLID45 elements. Degenerating cept for an offset in longitudinal direction amounting to the re-
these to wedges is not recommended since they are then less accu- quired displacement. With the specimen constrained in this
rate in high stress gradient regions [17], but it is tolerated in case of manner, rigid body motion is prevented. Further stabilization to
the bolts which are not subject to stress evaluation and created of the model is given through xation of the bolt in the symmetry
regular 8-node elements towards their outside. plane by very compliant springs. These are implemented as linear
LINK8 elements [17]. A symmetry constraint is applied to all nodes
4.2. Contact denitions belonging to the bolt and the specimen volumes that are located in
the symmetry plane. Since the used element types only feature
Interference of separate solid body FE entities, which do not translational degrees of freedom, only one degree of freedom nor-
share nodes, is made possible by dening contact elements. The mal to the symmetry plane is locked.
nodes that embody the outer surface of the volumes are shared Depending on the employed contact algorithms, a restriction
by the solid elements and contact and target elements for this pur- concerning degree of freedom constraints is necessary: If surface
pose. In absence of contact pairs, different separate volumes geo- body nodes are shared by a contact element that uses the Lagrange
metrically penetrate unrestrained. Surface-to-surface contact multiplier method, further constraining these nodes will lead to an
pairs that need to be dened in this model are: bolt shaft & washer over-constraint, due to conicting external boundary conditions
(radial), bolt head & washer face (axial), washer face & pulling
strap face, bolt shaft & pulling strap hole surface, pulling strap face
& specimen face, bolt shaft & specimen hole surface and SOLID45
part of specimen & SOLID46 part of specimen.
ANSYS provides a variety of contact algorithms which differ in
stiffness behavior both lateral and normal, penetration tolerance,
stability and convergence rate. As a default setting, most likely to
be applicable in various cases, ANSYS offers the augmented La-
grange method. Analyses carried out on an early version of this
model, incorporating only penalty method contact denitions with
default contact stiffness, exhibited extensive penetration between
the bolt shaft and both specimen and pulling strap. Another con-
tact algorithm provided by ANSYS is the Lagrange multiplier meth-
od. It enforces zero penetration by applying a geometrical
constraint relation and introducing the contact forces as additional
degrees of freedom, that are solved explicitly, rather than implic- Fig. 8. Detail of the specimen highlighting the radial and axial steady element
itly through contact stiffness and penetration. However, if a additional layers.
G. Kolks, K.I. Tserpes / Composites: Part A 56 (2014) 5163 57
t
90 90 mentation, are the most common potentially appropriate methods.
-45 -45
symm. 0 symm. 0 More information about numerical optimization algorithms can be
found in [20]. These algorithms, however, cannot be conveniently
B7 B8 applied to the present numerical model due to the fact that with
0 0
45 45 any method mentioned above, a great number of iterations, i.e. to-
0 0 tal simulation runs on the level of identication, are required. It is
90 90
-45 -45 therefore necessary to deviate from standard optimization algo-
symm. 0 symm. 0 rithms and make use of engineers experience and knowledge
about the system, in order to minimize the iterations involved. In
Fig. 11. Schematic description of the laminate layouts studied herein (t = 0.25 mm).
fact, the procedure adopted here for identication is a heuristic
manual approach, based on few assumptions and simplications.
6. Parameter identication
It is performed by iterating the sequence simulation runevalua-
tiondrawing conclusionsaltering parameters. As an additional
Due to the implementation as a gray-box model, an obligatory
instrument of evaluation, damage monitoring has been also imple-
step within the creation of the model is the determination of iden-
mented. This means, that in each simulation sub-step, for each fail-
tication parameters. Parameter identication is the process of
ure criterion the numbers of failed elements (with damage variable
matching numerical simulation results with data gained from mea-
di > 1) have been recorded to an array. Furthermore, for each lam-
surements by adjusting the identication parameters accordingly.
inate layer and each failure criterion, images that visualize the
failed elements can be generated at user-dened times during
6.1. Model specications of identication base
the analysis.
During the process of parameter identication, the operator can
For the model presented in this work, the identication base
account for the following principles:
comprises measurement plots of tensile tests conducted with four
different specimen layouts of a Ti-reinforced single-bolted CFRP-
If the simulated bearing stress in general exceeds the mea-
joint (see Fig. 11), with the geometrical parameters d = 6 mm,
sured data in the nonlinear domain, the stiffness residuals
w = 42 mm and e = 24 mm referring to the denitions illustrated
rij have to be reduced in total, and vice versa.
in Fig. 6. These measurement plots are given in [4] in terms of
Reducing rij of one failure criterion will impede further
nominal bearing stress against absolute cross-head displacement.
stress accumulation after the highest fail-rate for this crite-
Strength data of the used material M40-J/CYCOM977-2, specied
rion occurred. Here, the damage monitoring mentioned
ibid., are summarized in Table 3 and implemented into the set of
above is a helpful tool for controlling enhancement.
failure criteria involved. However, the exact layout of the pulling
Criteria that do not incorporate ber failure should not
strap and clamp mechanism are not sufciently known. Therefore,
entail degradation of stiffness terms other than those
in the model the pulling strap is kept short and during numerical
involving the normal of the fracture plane.
evaluation of the simulation data, a serial compliance element is
Material softening due to secondary failure may inhibit
included in order to t the linear slope in the low-displacement do-
ber failure.
main of the measurement curve. Note that in [4] the transitions be-
Coupling between two laminate layers is decreased by low-
tween the titanium replacement plies and CFRP plies are arranged
ering those shear stiffness terms involving the laminate
in a staggered form, in order to avoid notching effects. As opposed
normal. This affects the reinforcement capabilities by the
to that, in the model applied herein, all transitions are located in
titanium plies.
the same longitudinal coordinate. This is justiable by the fact that
Stress distribution around the bolt hole from the bearing
nonlinear effects in the transition region are not the focus of this
zone to the tensile loaded lateral zone is alleviated by low-
work and, as described above, the global compliance is manipu-
ering the in-plane shear stiffness.
lated in post-processing.
Table 4
Parameters retrieved from identication with a = 1 and nd = 2.
rij j
x y z xy yz xz
i MTF 1 0.012 1 0.0075 0.0075 1
MCF 1 0.012 1 0.0075 0.0075 1
DT 1 1 0.006 1 0.006 0.006
DC 1 1 0.006 1 0.006 0.006
FTF 0.008 1 1 0.008 0.008 0.008
FCF 4.8 106 1 1 4.8 106 4.8 106 4.8 106
Fig. 15. Comparison between simulation results and experimental data [4] of the parameter identication base.
0
Fig. 17. Course of normalized numbers of element failures (.1) and total numbers of element failures at Dx = 0.5 mm (.2) for B1 (a) and B7 (b) specimen respectively. (For
interpretation of the references to color in this gure legend, the reader is referred to the web version of this article.)
ber failures gain weight over the secondary failures. This particu- opposite effect can be found in the damage visualization for matrix
larly applies to ber tensile failure, whose total number increases tensile failure.
in the reinforced specimen layout. In spite of comparably low total The secondary failures show correlation with the occurrence of
failure count for this failure type, the higher step-like accumula- ber compressive failure in the adjacent layers. It is concluded that
tions of ber tensile failures apparently coincide with drops in secondary failure is additionally triggered by interlaminar shear
bearing strength (compare Figs. 15 and 16). Since softening and stress concentration that evolves from the stress gradients
through secondary failures is diminished by the titanium rein- caused by ber failure. The appearance of ber compressive failure
forcement, stresses are increasingly remote around the bolthole (see Fig. 19) is limited to areas in the projection of the bearing zone
leading to early ber failure in the lateral zone. However, the tita- along the ber direction of each layer. Fiber tensile failure exclu-
nium sheets increase the tolerance of ber failure thus, allowing sively occurs in low quantities in the lateral areas directly along-
for a further incline in bearing strength, which is in agreement side the bearing hole.
with reality. Similar damage plots depicting matrix compressive failure and
Evaluation of the area of failure propagation, that emerged in ber compressive failure are given in Fig. 20 for a titanium-rein-
the pure CFRP specimen after nal failure was detected, provides forced B7 specimen layout at a comparable displacement. The
information on the global failure mechanisms involved. In case of reduction of damaged area is an evident feature. particularly with
the secondary failure modes delamination and matrix failure, dam- regard to non-ber failure. These are limited to the longitudinal
age accumulates in the bearing pressure zone and propagates projections of the lateral hole edges where in-plane shear stress
towards the specimen longitudinal free edge in shape of a longitu- prevails and lack the asymmetric characteristic induced by the
dinal projection of the bolt hole. In this band, matrix compressive diagonal ber layers.
failure in the layers with diagonal ber direction particularly oc-
curs on the side where the plain shear stress caused by the central 8. Conclusions and outlook
bolt force contributes to matrix compression under consideration
of polar stress transformation. Areas of elements, exhibiting matrix A progressive damage model for the numerical representation
compressive failure at Dx0 = 0.64 mm, are depicted in Fig. 18. The of bearing effects in hybrid CFRP/Ti bolted joints has been
62 G. Kolks, K.I. Tserpes / Composites: Part A 56 (2014) 5163
0
Fig. 18. Visualization of failure after simulation of B1 specimen at Dx = 0.64 mm:
matrix compressive failure (MCF). (For interpretation of the references to color in
this gure legend, the reader is referred to the web version of this article.)
0
Fig. 20. Visualization of failure after simulation of B7 specimen at Dx = 0.58 mm:
matrix compressive failure (MCF) and ber compressive failure (FCF). (For
interpretation of the references to color in this gure legend, the reader is referred
to the web version of this article.)
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