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FINITE ELEMENT MODELING OF LAMINATED COMPOSITE PLATES WITH LOCALLY DELAMINATED INTERFACE SUBJECTED TO IMPACT LOADING SADDAM HUSSEIN ALI A project report submitted in fulfilment of the requirements for the award of the degree of Master of Engineering(Civil-Structure) Faculty of Civil Engineering Universiti Teknologi Malaysia June 2013
Transcript

FINITE ELEMENT MODELING OF LAMINATED COMPOSITE PLATES WITH

LOCALLY DELAMINATED INTERFACE SUBJECTED TO IMPACT LOADING

SADDAM HUSSEIN ALI

A project report submitted in fulfilment of the

requirements for the award of the degree of

Master of Engineering(Civil-Structure)

Faculty of Civil Engineering

Universiti Teknologi Malaysia

June 2013

iii

This project report is dedicated to my beloved parents.

iv

ACKNOWLEDGEMENT

First and foremost, I would like to express my thanks to Allah who is the one

that helped me and guided me finish this study on time. Second, I would like then to

express my sincere appreciation to my supervisor of this final year project, Dr.

Ahmad Kueh Beng Hong for his continuous guidance, professional advices, support,

motivation, and encouragement to complete this study.

Also, I would like to extend my thanks to my colleagues and friends,

especially Nadera Najib, Mohamud Abdilrahman, and Mohmed Saakhee for their

continuous support and help. Moreover, I would like to express my gratitude to

Universiti Teknologi Malaysia for the facilities and opportunities given to me to

pursue this study.

Last but not least, I would like to thank my parents and family for their

patience, support, prayers, and encouragement during this study.

v

ABSTRACT

This project report presents the finite element formulation for the

investigation of the effects of interface imperfection on the impact behavior of a

laminated composite plate. The interface condition between the laminas plays a very

important role in the determination of the behavior of the composite laminates. If the

bonding is imperfect, it has high possibility to delaminate progressively. Most of the

previous studies on laminated composites were carried out adopting the assumption

that the laminas are perfectly bonded. However, the existence of a perfect interfacial

bond in a real laminated composite seems to be impossible. Therefore, this study

aims to investigate the effect of localized interface imperfection on the behavior of a

laminated composite plate when subjected to low velocity impact loading for various

fiber orientations. A thin, flat, rectangular laminated plate with two layers of E-

glass/Epoxy transversely isotropic lamina and an orthotropic interface layer between

them are considered in this study. The interface is modeled as a layer of zero

thickness and zero mass, and the imperfection factor is applied locally to the

interface. By using MATLAB, the stiffness matrix, mass matrix, and the impact

force vector are formulated and programmed in order to obtain the deformation of

the plate. The results show that as the separation of fiber orientation between the two

laminas increases, both central deflection and energy absorption increase. The

increase of delamination area leads to plate’s damage due to the increase in the

absorbed energy, resulting in higher deformation.

vi

ABSTRAK

Laporan projek ini membentangkan rumusan unsur terhingga bagi menyiasat

kesan ketidaksempurnaan antaramuka pada tingkah laku impak plat komposit

berlapis. Keadaan antaramuka lamina memainkan peranan yang amat penting dalam

menentukan tingkah laku komposit berlapis. Jika ikatan tidak sempurna, ia

mempunyai kemungkinan yang tinggi untuk berpisah secara progresif. Kebanyakan

kajian terdahulu mengenai komposit berlapis telah dijalankan dengan menggunakan

andaian bahawa lamina adalah terikat dengan sempurna. Walaubagaimanapun,

kewujudan ikatan antaramuka yang sempurna dalam komposit berlapis sebenar

adalah mustahil. Oleh itu, kajian ini bertujuan untuk mengkaji kesan

ketidaksempurnaan setempat antaramuka pada kelakuan plat komposit berlapis

apabila dikenakan beban impak halaju rendah untuk pelbagai orientasi serat. Plat

berlapis segiempat nipis dan rata dengan dua lapisan isotropi melintang E-

kaca/epoksi dan lapisan antaramuka ortotropik telah dipertimbangkan dalam kajian

ini. Antaramuka telah dimodelkan sebagai lapisan ketebalan sifar dan berjisim sifar,

dan faktor ketidaksempurnaan telah dikenakan secara setempat kepada antaramuka.

Dengan menggunakan MATLAB, matriks kekukuhan, matriks jisim, dan vektor daya

impak telah dirumus dan diprogramkan untuk mendapatkan ubah bentuk plat.

Keputusan menunjukkan bahawa apabila pemisahan orientasi gentian antara kedua-

dua lamina meningkat, kedua-dua pesongan pusat dan penyerapan tenaga juga

meningkat. Peningkatan kawasan pemisahan membawa kepada kerosakan plat yang

disebabkan oleh peningkatan dalam tenaga yang diserap, dengan akibat ubah bentuk

yang lebih tinggi.

vii

TABLE OF CONTENTS

CHAPTER TITLE PAGE

DECLARATION ii

DEDECATION iii

ACKNOWLEGEMENT iv

ABSTRACT v

ABSTRAK vi

TABLE OF CONTENTS vii

LIST OF TABLES x

LIST OF FIGURES xi

LIST OF SYMBOLS xvi

1 INTRODUCTION 1

1.1 Background of Study 1

1.2 Problem Statement 4

1.3 Objective of the Study 5

1.4 Scope of the Study 5

1.5 Significance of the Study 6

2 LITERATURE REVIEW 8

2.1 General 8

2.2 Laminated Composite Materials 8

2.3 Applications of Laminated Composite Materials in Civil

Engineering. 10

viii

2.4 Laminated Composite Plates 12

2.5 The Behavior of Laminated Composite Plates Subjected to

Impact load 12

2.6 Factors Affecting the Behavior of Composite materials

under Impact load 17

2.6.1 The Laminate Properties Effect 18

2.6.2 Impactor Geometry 24

2.7 Previous Studies on the Interface Layer 26

3 METHODOLOGY 30

3.1 Introduction 30

3.2 Stiffness of the Lamina 32

3.3 Stiffness of the Interface 41

3.4 Element Stiffness Matrix of the Laminate 48

3.5 Global Stiffness Matrix of the Laminate 50

3.6 Computation of the Laminate Mass Matrix 53

3.7 Boundary Conditions 54

3.8 An Overview on the MATLAB Coding for this Study 55

4 RESULTS AND DISCUSSION 61

4.1 Introduction 61

4.2 Convergence Study 61

4.3 Verification of Study 63

4.4 The Effects of Fiber Orientation 64

4.4.1 Central Displacement 65

4.4.2 Relationship between Area of Delamination and

Maximum Central Displacement 68

4.4.3 Force-Displacement Relation of Various Laminates

Progressive Delamination 70

ix

4.5 Simulation of the Damage Behavior due to Blasting Studied

by Naik et al. (2006) 73

4.5.1 Central Displacement 75

4.5.2 The Relationship between Fiber Orientation and

Energy 79

5 CONCLUSIONS AND RECOMMENDATIONS 82

5.1 Conclusion 82

5.2 Recommendations 83

REFERENCES 85-90

Appendices A – E

x

LIST OF TABLES

TABLE NO.

TITLE PAGE

2.1

4.1

4.2

4.3

Example of the Use of Carbon Fiber in

Construction in Japan.

Precentage of difference of convergence study

Plate's properties and dimensions

Natural frequency of the eight mode shapes

11

62

63

64

v

LIST OF FIGURES

FIGURE NO. TITLE PAGE

1.1 Types of Fiber reinforced Composite

materials.

2

1.2 Sketch of the Interface 3

2.1 Use of CFRC panels in the Kita Kyusho

Prince Hotel

11

2.2 The effects of stacking sequence in

laminated composite plates.

13

2.3 Deformed shape of the laminated

composite folded plate under the impact

load.

14

2.4 Falling weight impact machine. 15

2.5 Pendulum impact test system 16

2.6 The gas-gun machine. 16

2.7 Delamination areas in both thick and thin

laminates.

19

2.8 Compression-after-impact strength in

both thick and thin laminates.

19

vi

2.9 Saturation energy versus number of layers

for the two stacking sequences.

20

2.10 Projectile shape and dimensions. 25

2.11 Displacement jumps and interlaminar

tractions interfaces.

27

2.12 Mechanical properties versus thickness

ratio for bonding layers.

28

2.13 Relationship between normalized stiffness

of composite system and the normalized

stiffness of the bonding layers.

28

3.1 The laminated composite plate subjected

to impact load

31

3.2 Finite Element Method (FEM) analytical

procedure for laminate composite plate

with an interface layer.

31

3.3 Distance of lamina surface from the mid

plane of laminate.

36

3.4 Coordinate system and degree of

freedoms (DOF) of lamina sub element.

37

3.5 Coordinate system of laminate plate

element

40

3.6 Coordinate system and degree of freedom

(DOF) in zero-thickness interface element

42

3.7 Degree of freedom (DOF) of each layer in

the laminate.

46

xiii

3.8. 2 x 2 Gaussian quadrature rules. 48

3.9 Degree of freedom (DOF) of the nodes in

each sub element.

49

3.10 Coordinate system of one local laminate

plate element and DOF at each node.

50

3.11 Rearrangement of node numbering. 51

3.12 Node global numbering. 51

3.13 Global nodes numbering for 2x2 elements 52

3.14 Input for plate information

56

3.15 Stiffness matrix of lamina

57

3.16 Stiffness matrix of interface

58

3.17 Mass matrix of lamina

59

3.18 Boundary condition. 59

3.19 Impact Force 60

4.1 Central deflection against number of

discretized elements

62

4.2 Displacement of laminate with 4×4

delamination

65

4.3 Displacement of laminate with 10×10

delamination

66

4.4 Displacement of laminate with 14×14

delamination

67

xiv

4.5 Relationship between area of

delamination and maximum displacement

for [0/0] laminate

68

4.6 Relationship between area of

delamination and maximum displacement

for [30/0] laminate

69

4.7 Relationship between area of

delamination and maximum displacement

for [50/0] laminate

69

4.8 Relationship between area of

delamination and maximum displacement

for [90/0] laminate

70

4.9 Force-displacement curve for [0/0]

laminate

71

4.10 Force-displacement curve for [30/0]

laminate

72

4.11 Force-displacement curve for [50/0]

laminate

72

4.12 Force-displacement curve for [90/0]

laminate

73

4.13 Naik et al. (2006) delamination behavior

74

4.14 Simulated delamination based on that of

Naik et al. (2006)

74

4.15 Displacement of laminate with [0/0]

orientation

76

4.16 Displacement of laminate with [30/0]

orientation

77

xv

4.17 Displacement of laminate with [50/0]

orientation

78

4.18 Displacement of laminate with [90/0]

orientation

79

4.19 Force-displacement curve for [0/0]

laminate

80

4.20 Force-displacement curve for [30/0]

laminate

80

4.21 Force-displacement curve for [50/0]

laminate.

81

4.22 Force-displacement curve for [90/0]

laminate

81

xvi

LIST OF SYMBOLS

Vf, Vm - Volume fraction of fiber and matrix respectively

Ef, Em - Young Modulus of fiber and matrix respectively

G12f, Gm - Shear modulus of fiber and matrix respectively

v12f, vm - Poisson’s ratio of fiber and matrix respectively

E1 - Longitudinal Young’s modulus

E2 - Transverse Young’s modulus

G12 - In-plane shear modulus

υ12 - Poisson’s ratio

ξ - Measure of fiber reinforcement of the composite that

depends on the fiber geometry, packing geometry, and

loading conditions. The value of ξ is taken as 2 for E2

calculation while 1 for G12 calculation.

Qij - Lamina stiffness matrix

Qij - Transformed stiffness matrix

N - In-plane force

M - In-plane moment

є0 - Mid-plane strain

xvii

κ - Mid-plane curvature

Aij, Bij, Dij - Laminate extensional stiffness, laminate-coupling

stiffness, and laminate-bending stiffness respectively

u, v, w - Displacement in x, y, z direction respectively

Øx, Øy - Rotation about the x, y direction respectively

Ni, No - Shape function for in-plane and out-of-plane degree of

freedom respectively

[B] - Element strain matrix

[K] - Element stiffness matrix

F - Force

q - Transversely distributed load

dlower - Interpolated displacement of node at lower surface of

the zero-thickness element

dupper - Interpolated displacement of node at upper surface of

the zero-thickness element

N - Lagrange shape function for zero-thickness element

lwd^

- Nodal displacement of node at lower surface of the zero-

thickness element

upd^

- Nodal displacement of node at upper surface of the zero-

thickness element

- Stress

- Strain

D - Constitutive matrix

h - Thickness of interface element

J - Jacobian matrix

xviii

ξ , η - Coordinate sysyem in Gauss quadrature rule

wi , wj - Weight of ith

and jth

Gauss point

f(ξi, ηj) - Function of ith

and jth

Gauss point

CHAPTER 1

INTRODUCTION

1.1 Background of the Study

Composite materials were introduced to several fields such as civil

engineering, aerospace engineering and transportation industry a few decades ago.

Composite materials are generally formed by combining two or more different

materials with different physical and chemical properties in a microscopic scale. The

combination of these materials produces a superior material that has all the properties

of the combined materials. Thus, a composite material can provide an easy approach

to design the right combination of fiber reinforcement and matrix material which

meets the desired specifications.

As a matter of fact, there are two types of fiber reinforced composite

materials as shown in Figure 1.1. The first type (Figure 1.1 (a)) is known as short

fiber-reinforced composite. This type is normally used in compression and sheet

moulding operations. The second type is referred to as continuous fiber-reinforced

composite and it is shown in Figure 1.1 (b). It is formed of a layered or laminated

structure. The applications of these fiber reinforced composites are usually used in

the form of plates and shells. Composite plates are always organized in a flat

laminate structure. Each layer of lamina contains an arrangement of unidirectional

fibers embedded within a thin layer of polymer matrix material. Since a single layer

of lamina has a very poor response to transverse tensile stress, each layer of lamina is

stacked together with another layer in order to eliminate the weakness in the

2

transverse direction. The fibers’ function is primarily to carry the load whereas the

matrix binds and protects fibers from any external damage. On the other hand, shells

are curved composite materials. They have higher structural stiffness compared to

plates in carrying loads and moments due to their curvature (Smith and Yeomans,

1995)

Figure 1.1 Types of fiber-reinforced composite material

During the manufacturing process of a laminate, a layer of adhesive (resin) is

applied between the adjacent laminas to bond them together into one plate. After the

application of the adhesive, the heat and pressure are introduced to the plate to make

the adhesive bond the adjacent layers together in a process known as the lamination

press process and the adhesive layer is called as the interface. Normally, the interface

between the laminate is expected to be perfectly bonded. However, the existence of a

perfect interfacial bond in a real laminated composite seems to be impossible.

Therefore, the interface adhesion is usually imperfect. This imperfection is

structurally harmful and contributes to the failure of the laminate when it is subjected

to impact loading. The defects greatly influence the performance and mechanical

properties of the laminate plate. The imperfection in the interface may be due to

incorrect amounts of adhesive or incorrect equipment setting during manufacturing.

3

Figure 1.2 shows the typical sketch of the interface (bonding) layer in a composite

laminate.

Figure 1.2 Sketch of the interface.

For structures prone to impacts or minor objects drop during assembly or

maintenance operation, composite laminates show a very brittle behavior and can

undergo serious damages such as matrix cracks, fibers breakages or delamination.

These damages are severe because they drastically reduce the mechanical

characteristics of the laminate and at the same time can leave visible marks onto the

impacted surface. The understanding of the interface imperfection effect on

laminated composite plates is of great importance in order to enable designers to

improve the plate’s strength. Since the most common failure mode in laminated

composite plates is delamination at the interface between the adjacent laminates, the

effect of imperfect bonding should be taken into consideration in analysis and design.

4

1.2 Problem Statement

For composite materials, the interface condition between the laminate plays a

very important role in the determination of the behavior of the composite laminates.

Most of the previous studies on laminated composite were carried out by adopting

the assumption that the laminas were perfectly bonded together. However, some

researchers have been studying the behavior of composite laminates with

interlaminar imperfections.

In most cases, imperfect bonding results in delamination. Delamination is

characterized as an insidious separation developed between laminas without being

seen on the surface. However, it is possible to detect delamination in the composite

material by using advanced techniques such as ultrasonic testing method (Collins,

2009).

It has been proven that the shape of a flat laminated plate subjected to a small

impact load in the transverse direction remains flat and in a state of equilibrium. As

the applied load gradually increases, small initial discontinuity starts to propagate

within the interface between adjacent laminates and results in a significant area of

delamination at the interface. When the magnitude of the impact load reaches

maximum, the configuration of the plate becomes unstable and the laminate starts to

fail (Yousefi et al, 2007).

As mentioned previously, most of the researches done so far are based on the

assumption that the interface of the composite plate is perfectly bonded. Currently,

there exists only a few studies that handle local interface imperfection problem. In

addition, the consideration is either at one location or total separation. Therefore, it

would be of great importance to study the behavior of the composite plate with local

imperfect interface subjected to impact loads.

5

1.3 Objective of the Study

The objectives of the study are:

1. To study the behavior of the laminated composite plates with a localized

delaminated interface when subjected to impact load for various fiber

orientations by means of finite element model.

2. To simulate the response due to the damage of the laminated composite plates

when impacted as that of Naik’s et al (2006).

1.4 Scope of the Study

The study is restricted to a rectangular laminate plate. The laminate plate is

considered to be thin and flat. It consists of two layers of lamina with equal thickness

and an interface layer between them. Each lamina is formed by unidirectional fibers

of E-glass and the matrix material is Epoxy (3501-6) with a volume fraction of 0.4.

The top layer of the lamina comprises fiber that varies in orientation from 0° to 90°

and the bottom layer of lamina comprises 0° fiber direction.

In this study, the lamina is considered as a transversely isotropic solid

material. By using a finite element method, the plate is modeled as a combination of

two laminas with the same boundary condition and thickness using Kirchoff’s

Classical Laminate Theory. Each node of the plate has five degrees of freedom,

which include displacement in x-direction (u), displacement in y-direction (v),

displacement in z-direction (w), rotation about y-direction (Øx) and rotation about x-

direction (Øy).

The interface layer between the two laminas is modeled as an orthotropic

material with zero normal stresses in x and y-directions (σx = 0 and σy = 0) and zero

in-plane shear stress in x-y plane (τxy = 0). The interface layer is modeled using

quadrilateral zero-thickness solid element with 8 nodes. Each node only considers

6

three degrees of freedom including displacement in x-direction (u), displacement in

y-direction (v), and displacement in z-direction (w). The stiffness matrices of the

laminas and interface element are computed using 2 by 2 Gauss quadrature rule. The

study only considers the impact of low velocity applied at the center of the plate with

fully clamped boundaries at all edges. In addition, this study does not take into

consideration the damping effect of the system.

1.5 Significance of the Study

For the last few decades, the application of laminated composite materials

such as plates and shells has been a point of interest in the industry of construction.

The reason behind that is the variety of properties possessed by laminates due to the

fact that they consist of different laminas and they offer mechanical properties that

depend on the fiber orientation. A lot of researches and studies have been

investigating the properties, behavior, strengths, and weaknesses of these laminated

composite materials resulting in tremendous advances in this field. However, there is

still a lot to investigate about these materials in order to optimize their usage in the

construction industry. One of the fields that still needs to be studied deeply is the

behavior of the laminated composite plates with local imperfect interface layer

subjected to impact loading. Generally, the composites are used in the form of

relatively thin plate. Therefore, load carrying capacity of laminated composite plate

with imperfect interface against impact is one of the significant concerns in the

stability analysis of a laminate structure. That is because most of the previous studies

were conducted with the assumption that the laminas are perfectly bonded and no

manufacturing defects. This assumption is inadequate since the interface layer has

imperfections due to the lamination process during manufacturing. Therefore, the

modeling of a laminated composite plate by considering imperfect interface will give

more accurate and better approach to the real behavior.

7

Finally, using finite element method to model such a complex behavior offers a very

convenient solution which saves time and effort. This behavior is considered

complex because it involves dynamic analysis due to impact loading.

85

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