experimental and numerical study on thermal aging and...
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MSC.Software VPD Conference | July 17-19, 2006 | Huntington Beach, California
Experimental and Numerical Study on Experimental and Numerical Study on Thermal Aging Thermal Aging andand Mechanical Mechanical
Properties of Properties of Composite Army BridgeArmy Bridge
Ayman Mosallam, Ph.D., P.E.University of California at Irvine, CA
Larry Russell, PH.D.Army Research Office, Research Triangle Park, NC
Ramki Iyer, MCEArmy-TARDEC, Warren, MI
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MSC.Software VPD Conference | July 17-19, 2006 | Huntington Beach, California
Project Team Members
Alpha Star Corp.
University of California, Irvine
The Boeing Company
Project Team Members
Alpha Star Corp.
University of California, Irvine
The Boeing Company
Project SponsorProject SponsorU.S. Army's Tank-
automotive and Armaments COMmand [TACOM]
U.S. Army's Tank-automotive and Armaments
COMmand [TACOM]
U.S. Army Research Office
[ARO]
U.S. Army Research Office
[ARO]
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MSC.Software VPD Conference | July 17-19, 2006 | Huntington Beach, California
OUTLINEThis presentation summarizes the activities that have been conducted during the a research project focusing on thermal aging of the military composite bridges.
The project was Funded by US Army Research Office (ARO)
COMPOSITECOMPOSITEARMYARMY
BRIDGE [CAB]BRIDGE [CAB]
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MSC.Software VPD Conference | July 17-19, 2006 | Huntington Beach, California
Assault BridgingAssault Bridging
Wolverine BridgeWolverine Bridge
Armored Vehicle Launched Bridge
Armored Vehicle Launched Bridge
Improved Ribbon BridgeImproved Ribbon Bridge
Standard Ribbon BridgeStandard Ribbon Bridge
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MSC.Software VPD Conference | July 17-19, 2006 | Huntington Beach, California
BackgroundMilitary composite bridges offer many unique
advantages for the army including
lightweight weight (high strength-to-weight ratio),
superior corrosion resistance properties that are preferred in harsh environmental conditions.
The lightweight features of composite is an attractive and essential property fulfilling the goal of the US Army in producing lighter bridging components that require
less skill/craftsmanship to manufacture, less equipment and manpower to transport and repair
as well as being cost effective in the long run.
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MSC.Software VPD Conference | July 17-19, 2006 | Huntington Beach, California
Allowable or Negligible Damage
Interim Interim
Repairable Damage
TYPES OF DAMAGES
Major or Irreparable Damage
Temporary Temporary
Allowable or Negligible Damage
Interim Interim
Repairable Damage
TYPES OF DAMAGESTYPES OF DAMAGES
Major or Irrepairable Damage
Temporary Temporary
Permanent
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MSC.Software VPD Conference | July 17-19, 2006 | Huntington Beach, California
Diagnostic/Prognostic System (DPS) Concept
• The DPS system is designed such that the strain and other useful signals captured by the optical fiber sensors are transmitted remotely via a cellular phone line or other communication devices.
• Real-time field information are transmitted to different monitoring and control locations [e.g. bridging unit forward base or army headquarters.]
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MSC.Software VPD Conference | July 17-19, 2006 | Huntington Beach, California
Divert
Pass Slowly
Pass
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MSC.Software VPD Conference | July 17-19, 2006 | Huntington Beach, California
GENOA Full Hierarchical Modeling from Structural Scale to Micro-scale
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MSC.Software VPD Conference | July 17-19, 2006 | Huntington Beach, California
Collaborative Virtual testing (CVT) Website Collaborative Virtual testing (CVT) Website
Live Data Transmission and Analysis Live Data Transmission and Analysis -- 22
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MSC.Software VPD Conference | July 17-19, 2006 | Huntington Beach, California
What accuracy is availableWhat accuracy is available
What detail can be providedWhat detail can be provided
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MSC.Software VPD Conference | July 17-19, 2006 | Huntington Beach, California
Moving Loads Cyclic Laboratory (Real) & Computer-Simulated (Virtual) Tests of the Composite Army Bridge
Filed testing Filed testing --Progressive Fatigue Failure Analysis Progressive Fatigue Failure Analysis
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MSC.Software VPD Conference | July 17-19, 2006 | Huntington Beach, California
1 9 . 9 2 8 . 7 1 2 1 . 3 7 1 4 . 9 2 2 4 . 4 11 0 . 6 8
1 9 . 9 28 . 7 12 1 . 3 71 4 . 9 22 4 . 4 1
1 0 . 6 8
S u p p o r t B lo c k T r e a d w a y
D is t r i b u t o r B e a m
W h i f f le T r e e
A c t u a t o r
L o a d B lo c k s I n t e r n a l B u lk h e a d s
Max Moment Case [Loading Case 2]
Max Moment Case Max Moment Case [Loading Case 2][Loading Case 2]
Actuator Load and Displacements (ultimate Test)
What behaviors can be examinedWhat behaviors can be examined
Progressive Failure
Analysis of Composite
Bridge
Comparison between Full-Scale Experimental and GENOA Predicted Results for Load Case 2 (Max Moment)
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MSC.Software VPD Conference | July 17-19, 2006 | Huntington Beach, California
Thermal Aging Test MatrixThermal Aging Test MatrixStatic Tension
Static Compression
T/C Fatigue
Double V-Notch Shear
Group 1
Group 5Control
No-Load Thermal Aging Impact
No-Load Thermal Aging
Pre-Tension Thermal Aging
Pre-Compress Thermal Aging
UV Exposure
Static Tension
Static Compression
T/C Fatigue
Double V-Notch Shear
Group 2
Group 3
Group 4
Group 6
Flexural Creep
Double Notch Shear Creep
Group 7
Creep
Static Tension
Static Compression
T/C Fatigue
Double V-Notch Shear
Static Tension
Static Compression
T/C Fatigue
Double V-Notch ShearStatic Tension
Static Compression
T/C Fatigue
Double V-Notch Shear
Static Tension
Static Compression
T/C Fatigue
Double V-Notch Shear
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MSC.Software VPD Conference | July 17-19, 2006 | Huntington Beach, California
Results Results –– Control Case: Static PropertiesControl Case: Static Properties
Control – Mechanical Test and Simulation Prior to Thermal Cycling or UV Exposure
OCM Test Previous Seemann Test GENOA Simulation Property Modulus
(msi) Strength
(ksi) Modulus
(msi) Strength
(ksi) Modulus
(msi) Strength
(ksi) Tension 10.4 94.4 7.8 101.0 8.2 98.0 Compression 10.3 74.0 7.8 75.8 8.2 73 Shear 2.0 23.4 N/A N/A 3.3 26.4
GENOA simulation for this material was performed using the constituent properties derived from the Seemann test data.
The numerical predictions for the composite static properties inthe OCM tests are successful.
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MSC.Software VPD Conference | July 17-19, 2006 | Huntington Beach, California
Results Results –– Control Case: Evaluation of the Shear Test Using Control Case: Evaluation of the Shear Test Using GENOAGENOA
Failed around gripped areas
Shear stress distribution
Fractured areas
TestSimulation
Shear test was not successful due to the wrong failure location.
The reason for this failure is because the shear stress in the grip area is higher than the shear stress in the notched area.
The ASTM D 5379 shear test is not valid for this tri-axial material.
The Iosipescu shear test and simulation results are not reported in the subsequent sections due to the reasons above.
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MSC.Software VPD Conference | July 17-19, 2006 | Huntington Beach, California
Results Results –– Control Case: Fatigue Properties, and Effect of NoControl Case: Fatigue Properties, and Effect of No--Load Thermal CyclingLoad Thermal Cycling
0
0.2
0.4
0.6
0.8
1
1.E+02 1.E+03 1.E+04 1.E+05 1.E+06 1.E+07 1.E+08Fatigue Cycle
Stre
ss L
evel
(Rat
io to
the
Tens
ile S
tren
gth)
Test-ControlTest - After No Load Thermal CyclingGENOA
T/C (R=-1) Fatigue(50 Cycles from (50 Cycles from ––27.4 F to 159.8 F)27.4 F to 159.8 F)
0
0.2
0.4
0.6
0.8
1
1.E+02 1.E+03 1.E+04 1.E+05 1.E+06 1.E+07 1.E+08
Fatigue Cycle
Stre
ss L
evel
(Rat
io to
the
Tens
ile S
tren
gth)
Test-Control
GENOA-Control
Run Out. Test Stopped without Failure
T/C (R=-1) Fatigue
Matrix S-N degradation was derived based on this fatigue test.
Excellent match between simulation and test demonstrates the derived matrix S-N relation reflects the matrix fatigue behavior accurately.
Simulation indicates there was no damage that occurred during the thermal cycling process .
Test curve for the no load thermal cycling case is a little higher than the control, which must be caused by test scattering.
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MSC.Software VPD Conference | July 17-19, 2006 | Huntington Beach, California
Results Results –– Effect of PreEffect of Pre-- Tension and Compression Thermal Tension and Compression Thermal CyclingCycling
0
0.2
0.4
0.6
0.8
1
1.E+02 1.E+03 1.E+04 1.E+05 1.E+06 1.E+07 1.E+08
Fatigue Cycle
Stre
ss L
evel
(Rat
io to
the
Tens
ile S
tren
gth)
Test-ControlTest - After Pre Tension Thermal CyclingGENOA
(30% of the UTS, 50 Cycles from (30% of the UTS, 50 Cycles from ––27.4 F to 159.8 27.4 F to 159.8 F) on Composite Fatigue PropertiesF) on Composite Fatigue Properties
0
0.2
0.4
0.6
0.8
1
1.E+02 1.E+03 1.E+04 1.E+05 1.E+06 1.E+07 1.E+08
Fatigue CycleSt
ress
Lev
el (R
atio
to th
e Te
nsile
Str
engt
h)
Test-ControlTest - After Pre Compression Thermal CyclingGENOA
(30% of the UTC, 50 Cycles from (30% of the UTC, 50 Cycles from ––27.4 F to 159.8 27.4 F to 159.8 F) on Composite Fatigue PropertiesF) on Composite Fatigue Properties
Simulation indicates there was no damage that occurred during thermal cycling.
n sufficient reason to conclude that 50 pre-tension thermal cycles reduced the composite fatigue life.
Composite static tensile strength after 50 thermal cycles is a little higher than the control case, which may indicate the fatigue life variation is probably caused by material variation .
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MSC.Software VPD Conference | July 17-19, 2006 | Huntington Beach, California
Results Results –– Effect of NoEffect of No--Load Thermal Cycling (50 Cycles from Load Thermal Cycling (50 Cycles from ––27.4 F to 159.8 F): Impact Investigation27.4 F to 159.8 F): Impact Investigation
Diameter of the impactor head: 0.625 inches
Weight of the impactor: 10.8 pounds
Drop height of the impactor: 30.8 inches
Achieved impact energy (unit plate thickness): 1500 in-pound/in
1 inch
Test
Red area is the simulated damage area
Damage Areas in the Panel after Impact. The test picture is a C-Scan graph (2 ¼ MHZ. Ultrasonic Thru-Transmission C-Scan).
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MSC.Software VPD Conference | July 17-19, 2006 | Huntington Beach, California
Results Results –– Effect of NoEffect of No--Load Thermal Cycling, and Ultra VioletLoad Thermal Cycling, and Ultra Violet
(50 Cycles from (50 Cycles from ––27.4 F to 159.8 F) and 27.4 F to 159.8 F) and Impact on Composite Fatigue Properties
(313-Bulb Ultra Violet for 750 hours ) on Composite Fatigue PropertiesImpact on Composite Fatigue Properties
0
0.2
0.4
0.6
0.8
1
1.E+02 1.E+03 1.E+04 1.E+05 1.E+06 1.E+07 1.E+08
Fatigue Cycle
Stre
ss L
evel
(Rat
io to
the
Tens
ile S
tren
gth)
Test-ControlTest - After ImpactGENOA-ControlGENOA - After Impact
0
0.2
0.4
0.6
0.8
1
1.E+02 1.E+03 1.E+04 1.E+05 1.E+06 1.E+07 1.E+08
Fatigue CycleSt
ress
Lev
el (R
atio
to th
e Te
nsile
Str
engt
h)
Test-ControlTest - After UVGENOA-ControlGENOA - After UV
The higher fatigue life of the composite after UV exposure should be caused by the material variability or due to test scattering.
GENOA simulation shows the 750-hour UV exposure did not influence the composite fatigue life
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MSC.Software VPD Conference | July 17-19, 2006 | Huntington Beach, California
Estimating the PostEstimating the Post--fire Strengthfire Strength1. Apply the thermal load as fire to the CAB deck2. The temperature distribution is used as inputs to progressive failure analyzer to evaluate the
damage due to fire. 3. Afterwards, the ultimate load is estimated as the post-fire residual strength with the damage
index imported to CAB progressive failure analysis model, and max shear loading case is applied.
Thermal load MSC.Nastran/Thermal Analysis
Temperature Distribution
GENOA/PFA Damage Pattern & Location
GENOA/PFAUltimate load (the Post-fire Residual
Strength)MaxShear Load
Stage 1:
Stage 2:
Stage 3:
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MSC.Software VPD Conference | July 17-19, 2006 | Huntington Beach, California
Internal damage distribution and damage pattern thirty Internal damage distribution and damage pattern thirty minutes after fire exposureminutes after fire exposure
Temperature Distribution was mapped to PFA modelMaterial properties (stiffness and Strength) were degraded with respect to temperature by Multi Factor Interaction ModelFailure modes and damage location, were assed by PFA
What behaviors can be examinedWhat behaviors can be examined
Damage distribution and pattern Damage distribution and pattern thirty minutesthirty minutes after fire exposureafter fire exposure
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MSC.Software VPD Conference | July 17-19, 2006 | Huntington Beach, California
Delamination in the Bulkhead, Crossover, and Beam Wall Surface
What behaviors can be examined What behaviors can be examined –– 1212
Resin damage in TBHB
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MSC.Software VPD Conference | July 17-19, 2006 | Huntington Beach, California
Thank you for your attention/Ayman