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At least 397 records · Page 22
All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

Interlaminar R-Curve Effects in Thermoplastic Composites: Experiments and Model Correlations

The interlaminar fracture behavior of thermoplastic composites under Mode-I and Mode-II static loading is investigated in this research. The material system under consideration is a carbon fiber reinforced low melt semi-crystalline resin TC1225 LMPAEK T700G (T700/LMPAEK)†. Characterization experiments were conducted to measure the load-displacement response, peak load, and propagation of delamination from a pre-implanted Kapton® insert. The Mode-I response was characterized using a double cantilever beam (DCB) test according to the ASTM D5528-22 standard. It was observed that the propagation exhibited significant resistance to delamination growth, i.e., an R-Curve effect. The test data indicated that the steady-state fracture toughness, G SS I , was approximately twice the mean initiation fracture toughness, G Ic . The Mode-II response of an end notch flexure (ENF) specimen tested according to the ASTM D7905-19 standard exhibited an unexpected stable behavior upon attaining peak load. Prior to attaining peak load, the Mode-II response exhibited some non-linearity, which may be attributed to nonlinear bulk material response, e.g., hyper-elasticity, viscoelasticity, plasticity, etc., and potentially friction at the load/support rollers and R-Curve effects. Finite element models based on the Cohesive Zone Method (CZM) and the Virtual Crack Closure Technique (VCCT) were used to predict the DCB and ENF specimen responses. DCB analysis results obtained using G SS I predicted propagation consistent with experimental data. However, results obtained with the as characterized G Ic were inaccurate in predicting delamination growth onset and peak load. ENF analysis results obtained with the as-characterized Mode-II fracture toughness, G IIc , were inaccurate in predicting the peak load and propagation. Hence, R-Curve effects were included in both DCB and ENF simulations, which enabled improved predictions. The experimentally determined Mode-I R-Curve was used for the DCB simulations, whereas an R-Curve was derived for Mode-II assuming that the change in compliance of the specimen was associated with crack growth only.

Prabhakar M Rao↗
NASA NTRSDate not supplied

Interlaminar R-Curve Effects in Thermoplastic Composites: Experiments and Model Correlations

The interlaminar fracture behavior of thermoplastic composites under Mode-I and Mode-II static loading is investigated in this research. The material system under consideration is a carbon fiber reinforced low melt semi-crystalline resin TC1225 LMPAEK T700G (T700/LMPAEK)†. Characterization experiments were conducted to measure the load-displacement response, peak load, and propagation of delamination from a pre-implanted Kapton® insert. The Mode-I response was characterized using a double cantilever beam (DCB) test according to the ASTM D5528-22 standard. It was observed that the propagation exhibited significant resistance to delamination growth, i.e., an R-Curve effect. The test data indicated that the steady-state fracture toughness, G SS I , was approximately twice the mean initiation fracture toughness, G Ic . The Mode-II response of an end notch flexure (ENF) specimen tested according to the ASTM D7905-19 standard exhibited an unexpected stable behavior upon attaining peak load. Prior to attaining peak load, the Mode-II response exhibited some non-linearity, which may be attributed to nonlinear bulk material response, e.g., hyper-elasticity, viscoelasticity, plasticity, etc., and potentially friction at the load/support rollers and R-Curve effects. Finite element models based on the Cohesive Zone Method (CZM) and the Virtual Crack Closure Technique (VCCT) were used to predict the DCB and ENF specimen responses. DCB analysis results obtained using G SS I predicted propagation consistent with experimental data. However, results obtained with the as characterized G Ic were inaccurate in predicting delamination growth onset and peak load. ENF analysis results obtained with the as-characterized Mode-II fracture toughness, G IIc , were inaccurate in predicting the peak load and propagation. Hence, R-Curve effects were included in both DCB and ENF simulations, which enabled improved predictions. The experimentally determined Mode-I R-Curve was used for the DCB simulations, whereas an R-Curve was derived for Mode-II assuming that the change in compliance of the specimen was associated with crack growth only.

Prabhakar Rao↗
NASA NTRSDate not supplied

Automated Multi-Robot Assembly of Compliance Optimized Structures

Autonomous assembly of large structures is one of the fundamental challenges on the way towards NASA’s objectives of deep space exploration. In this work, we propose an algorithmic framework to optimize the assembly process of a prescribed target structure by constraining the assembly effort as well as maintaining structural soundness throughout the process. This framework uses structural topology optimization with assembly effort metrics to generate checkpoints for robotic traversal algorithms. Assembly effort is quantified by the Wasserstein metric between consecutive structural configurations during the assembly process. The robotic assembly task is split into two subtasks, where we first optimize for a set of key frames, then perform reconfiguration between consecutive frames. Key frames are optimized by adopting topology optimization techniques to reduce assembly effort and maintain structural integrity during the assembly process, while reconfiguration between key frames is performed using a path planning algorithm with a minimum weight maximum matching approach on a bipartite graph. We employ a Crystalline robot model in which each structural element is capable of locomotion through the structure and locking into place with neighboring elements after reaching its destination. An example assembly of a two-dimensional cantilever beam under volume constraints and structural compliance considerations is presented to demonstrate the approach. Finally, we conclude by discussing possible future extensions to this work, including adoption of better metrics, extension to three-dimensional large-scale problems, and exacting finer control of structural integrity during the path-planning phase.

robotic assembly↗
NASA NTRSDate not supplied

Development of a Combined Cohesive and Virtual Crack-Closure Technique Approach to Represent R-Curves

Resistance curve (R-curve) effects due to fiber bridging, crack migration, and other blunting mechanisms are common in composite laminates. These mechanisms can dramatically increase the resistance to crack propagation but can be challenging to simulate. Delamination with R-curves can be analyzed using cohesive zone modeling (CZM) or the virtual crack closure technique (VCCT). Large fracture process zones can be simulated with CZM, but they require highly refined meshes. Coarser meshes can be used with VCCT, but this method is only applicable to small fracture process zones with R-curves defined as functions of position. Therefore, a technique with the computational efficiency of VCCT and the natural ability of cohesive elements to represent large fracture process zones is desirable. An approach is proposed that starts as a CZM in which the cohesive traction separation law (TSL) is separated into high-strength (HS) and low-strength (LS) components. The HS part, which is responsible for the mesh requirements of the CZM analysis, is replaced by VCCT. The combined method is evaluated by analyzing the response of double cantilevered beam specimens. Two specimen layup configurations, [0/90/90/0] 3s and [0/90/90/0] 9s , are evaluated. The R-curve response from each configuration is determined and applied to the constitutive properties of models built with CZM and with VCCT. The results and computational efficiency of the CZM, VCCT, and combined approaches are compared. The results are indicative that a combined cohesive/VCCT approach can enable progressive failure analyses to retain the computational efficiency of VCCT with the ability of the cohesive elements to capture R-curve effects.

Virtual Crack-Closure Technique↗
NASA NTRSDate not supplied

Analysis of Crack Propagation Transients in Accelerated Fatigue Characterization of Adhesives

The characterization of the rates of crack propagation by means of a Paris law is intended for steady-state fatigue conditions. While rates of crack propagation are primarily driven by 𝐽𝐽𝑚𝑚𝑚𝑚𝑚𝑚, in the presence of evolving process zones and fiber bridging they also depend on the crack propagation length: cracks with fully formed process zones propagate more slowly. Analyses of the rates of crack propagation in laminates secondarily bonded with AF163-2K film adhesive were conducted to identify the rate transients that occur during the formation of the process zone in the adhesive and during the evolution of bridging of the adhesive’s carrier knit across the crack faces. Dávila's CF22 cohesive fatigue damage model was used in finite element analyses of the double cantilever beam test to explain discrepancies in experimental rates of propagation obtained from tests conducted with either increasing or decreasing 𝐽max. The results indicate that the analyses accurately reproduce transient and steady-state rates of propagation observed in the experimental results, as well as the threshold of propagation. Transient rates of propagation always exceed those in steady state, which underscores the need to understand transients and account for them in fatigue characterization. The results also highlight that a Paris curve for steady-state propagation can be obtained most quickly using a decreasing load function, but that this curve consists of an unconservative bound to the rates of propagation. A lateral shift in the Paris curve is proposed for a conservative characterization that removes the effect of bridging and other R-curve effects.

fracture mechanics; delamination; J-integral↗
NASA NTRSDate not supplied

Analysis of Crack Propagation Transients in Accelerated Fatigue Characterization of Adhesives

The characterization of the rates of crack propagation by means of a Paris law is intended for steady-state fatigue conditions. While rates of crack propagation are primarily driven by 𝐽𝐽𝑚𝑚𝑚𝑚𝑚𝑚, in the presence of evolving process zones and fiber bridging they also depend on the crack propagation length: cracks with fully formed process zones propagate more slowly. Analyses of the rates of crack propagation in laminates secondarily bonded with AF163-2K film adhesive were conducted to identify the rate transients that occur during the formation of the process zone in the adhesive and during the evolution of bridging of the adhesive’s carrier knit across the crack faces. Dávila's CF22 cohesive fatigue damage model was used in finite element analyses of the double cantilever beam test to explain discrepancies in experimental rates of propagation obtained from tests conducted with either increasing or decreasing 𝐽max. The results indicate that the analyses accurately reproduce transient and steady-state rates of propagation observed in the experimental results, as well as the threshold of propagation. Transient rates of propagation always exceed those in steady state, which underscores the need to understand transients and account for them in fatigue characterization. The results also highlight that a Paris curve for steady-state propagation can be obtained most quickly using a decreasing load function, but that this curve consists of an unconservative bound to the rates of propagation. A lateral shift in the Paris curve is proposed for a conservative characterization that removes the effect of bridging and other R-curve effects.

fracture mechanics; delamination; J-integral↗
DOE OSTI2022

Mode I fracture testing fixture

An apparatus and method for preparing Double Cantilever Beam (DCB) specimens are disclosed as an apparatus and method for conducting Mode I fracture resistance testing using the DCB specimens. In a first embodiment, a drill jig is used to locate the DCB specimen and guide a drilling process during creation of at least one through-hole in the DCB specimen. The drilling process may employ a traditional drill and drill bit, a laser drill, or a water jet. In another embodiment, a set of rotating pin blocks, each with a full-round or a half-round specimen pin at one end and a hanger full-round pin at the other end, engage the DCB specimen and facilitate the internal application of a fracturing load to the DCB specimen for the Mode I fracture resistance test. The present invention may significantly reduce the time and materials needed to prepare and test a DCB specimen.

Briggs, Timothy↗
DOE OSTI2023

Mode I fracture testing fixture

An apparatus and method for preparing Double Cantilever Beam (DCB) specimens are disclosed as an apparatus and method for conducting Mode I fracture resistance testing using the DCB specimens. In a first embodiment, a drill jig is used to locate the DCB specimen and guide a drilling process during creation of at least one through-hole in the DCB specimen. The drilling process may employ a traditional drill and drill bit, a laser drill, or a water jet. In another embodiment, a set of rotating pin blocks, each with a full-round or a half-round specimen pin at one end and a hanger full-round pin at the other end, engage the DCB specimen and facilitate the internal application of a fracturing load to the DCB specimen for the Mode I fracture resistance test. The present invention may significantly reduce the time and materials needed to prepare and test a DCB specimen.

Briggs, Timothy↗
NASA NTRS2012

Improved Displacement Transfer Functions for Structure Deformed Shape Predictions Using Discretely Distributed Surface Strains

In the formulations of earlier Displacement Transfer Functions for structure shape predictions, the surface strain distributions, along a strain-sensing line, were represented with piecewise linear functions. To improve the shape-prediction accuracies, Improved Displacement Transfer Functions were formulated using piecewise nonlinear strain representations. Through discretization of an embedded beam (depth-wise cross section of a structure along a strain-sensing line) into multiple small domains, piecewise nonlinear functions were used to describe the surface strain distributions along the discretized embedded beam. Such piecewise approach enabled the piecewise integrations of the embedded beam curvature equations to yield slope and deflection equations in recursive forms. The resulting Improved Displacement Transfer Functions, written in summation forms, were expressed in terms of beam geometrical parameters and surface strains along the strain-sensing line. By feeding the surface strains into the Improved Displacement Transfer Functions, structural deflections could be calculated at multiple points for mapping out the overall structural deformed shapes for visual display. The shape-prediction accuracies of the Improved Displacement Transfer Functions were then examined in view of finite-element-calculated deflections using different tapered cantilever tubular beams. It was found that by using the piecewise nonlinear strain representations, the shape-prediction accuracies could be greatly improved, especially for highly-tapered cantilever tubular beams.

Ko, William L.↗
NASA NTRS1990

An experimental modal testing/identification technique for personal computers

A PC-based system for mode shape identification is evaluated. A time-domain modal identification procedure is utilized to identify the mode shapes of a beam apparatus from discrete time-domain measurements. The apparatus includes a cantilevered aluminum beam, four accelerometers, four low-pass filters, and the computer. The method's algorithm is comprised of an identification algorithm: the Eigensystem Realization Algorithm (ERA) and an estimation algorithm called Minimum Model Error (MME). The identification ability of this algorithm is compared with ERA alone, a frequency-response-function technique, and an Euler-Bernoulli beam model. Detection of modal parameters and mode shapes by the PC-based time-domain system is shown to be accurate in an application with an aluminum beam, while mode shapes identified by the frequency-domain technique are not as accurate as predicted. The new method is shown to be significantly less sensitive to noise and poorly excited modes than other leading methods. The results support the use of time-domain identification systems for mode shape prediction.

Roemer, Michael J.↗
NASA NTRS2015

Variable-Domain Displacement Transfer Functions for Converting Surface Strains into Deflections for Structural Deformed Shape Predictions

Variable-Domain Displacement Transfer Functions were formulated for shape predictions of complex wing structures, for which surface strain-sensing stations must be properly distributed to avoid jointed junctures, and must be increased in the high strain gradient region. Each embedded beam (depth-wise cross section of structure along a surface strain-sensing line) was discretized into small variable domains. Thus, the surface strain distribution can be described with a piecewise linear or a piecewise nonlinear function. Through discretization, the embedded beam curvature equation can be piece-wisely integrated to obtain the Variable-Domain Displacement Transfer Functions (for each embedded beam), which are expressed in terms of geometrical parameters of the embedded beam and the surface strains along the strain-sensing line. By inputting the surface strain data into the Displacement Transfer Functions, slopes and deflections along each embedded beam can be calculated for mapping out overall structural deformed shapes. A long tapered cantilever tubular beam was chosen for shape prediction analysis. The input surface strains were analytically generated from finite-element analysis. The shape prediction accuracies of the Variable- Domain Displacement Transfer Functions were then determined in light of the finite-element generated slopes and deflections, and were fofound to be comparable to the accuracies of the constant-domain Displacement Transfer Functions

displacement transfer functions↗
NASA NTRS2011

Extension of Ko Straight-Beam Displacement Theory to Deformed Shape Predictions of Slender Curved Structures

The Ko displacement theory originally developed for shape predictions of straight beams is extended to shape predictions of curved beams. The surface strains needed for shape predictions were analytically generated from finite-element nodal stress outputs. With the aid of finite-element displacement outputs, mathematical functional forms for curvature-effect correction terms are established and incorporated into straight-beam deflection equations for shape predictions of both cantilever and two-point supported curved beams. The newly established deflection equations for cantilever curved beams could provide quite accurate shape predictions for different cantilever curved beams, including the quarter-circle cantilever beam. Furthermore, the newly formulated deflection equations for two-point supported curved beams could provide accurate shape predictions for a range of two-point supported curved beams, including the full-circular ring. Accuracy of the newly developed curved-beam deflection equations is validated through shape prediction analysis of curved beams embedded in the windward shallow spherical shell of a generic crew exploration vehicle. A single-point collocation method for optimization of shape predictions is discussed in detail

Ko, William L.↗