towards a new paradigm for high- fidelity … · multi-scale modelling of composite substructures...

TOWARDS A NEW PARADIGM FOR HIGH-FIDELITY TESTING AND INTEGRATED

MULTI-SCALE MODELLING OF COMPOSITE SUBSTRUCTURES AND COMPONENTS

Janice Dulieu-Barton & Ole Thybo ThomsenFaculty of Engineering and the Environment

University of Southampton

International Symposium Novel Composite Materials & Processes for Offshore Renewable Energy. Cork, 1 September 2017

PresenterPresentation NotesPlease use the dd month yyyy format for the date for example 11 January 2008. The main title can be one or two lines long.

Outline Background and motivation

Aims & objectives the Vision

High fidelity substructure testing methodology (demonstrator: wind turbine blade substructure)

Strain based NDE methodology TSA & LIDIC integration (demonstrator - CFRP spar corner)

Future directions and final comments

2

Background and motivationBuilding block approach OR testing pyramid

1. Coupon: a small test specimen for evaluation of basic laminate properties or properties of generic structural features

2. Element: A generic part of a more complex structural member

3. Detail/Component: a non-generic structural element of a more complex structural member

4. Component/Full structure: major three-dimensional structure - complete structural representation of a section of the full structure (or the full structure)

3

HOWEVER - building block approach has severe limitations

Evidence

Conventional failure models are based on inputs derived from coupon tests comprising simple, mainly uniaxial, loading modes and unidirectional materials

Building block approach:

Large number of coupon tests to define allowables -relatively few tests at larger scales (elements to full structure)

Underlying assumption: material properties from tests at the coupon level can be used to define design allowables at greater length scales

Coupon properties do not represent the in-situ properties well

Coupon level failure data does not correlate well with failure behaviour observed on component and substructure levels

Defects and geometrical artefacts/details are not well-represented in coupon specimens

4

Aims & Objectives the VisionDevise a methodology referred to as integrated high fidelity testing and multi-scale analysis to include:

Measurement and simulation of complex multiaxial deformation states and the corresponding loading conditions

Quantitative characterisation of the limit states that lead/contribute to failure on higher (structural) length scale levels

Output from tests at higher length scales used for updating the computational models

Validated data for failure under multiaxial stress states -improving predictions of failure models

Laustsen, S., Lund, E., Khlmeier, L. and Thomsen, O.T. (2013) Development of a high-fidelity experimental substructure test rig for grid-scored sandwich panels in wind turbine blades Strain, 50, (2), pp. 111-131. (doi:10.1111/str.12072).

Laustsen, S., Lund, E., Kuhlmeier, L. and Thomsen, O.T. (2014) Failure behaviour of grid-scored foam coredcomposite sandwich panels for wind turbine blades subjected to realistic multiaxial loading conditionsJournal of Sandwich Structures and Materials, 16, (5), pp. 481-510. (doi:10.1177/1099636214541367).

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http://dx.doi.org/10.1111/str.12072http://dx.doi.org/10.1177/1099636214541367

Methodology demonstrator: wind turbine blade substructure

6

Definition of load and displacement boundary conditions

Geometrically nonlinear FE analysis (solid shell elements)

7

Full scale results are translated into local loading conditions

Substructure test specimen

8

Pulsating biaxial compression loading (cyclic fatigue)

10

Global and local FE model predictions vs. DIC measurements for the biaxial compression case

12

Post mortem images showing through-thickness (z direction) cracks in the longitudinal resin bridge when subjected to the multi-axial tension load case.

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Strain based NDE methodology TSA & LIDIC integration Demonstrator: CFRP spar corner

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Devise a high fidelity means of obtaining local strain/stress data to inform model-based prognostics to define how a given defect will evolve under service load Demonstrate the viability of the experimental methodology

providing the data necessary for a model based prognosis system

Demonstrate the approach at a sub-structural level Demonstrate high-fidelity modelling capability onset of

failure of composite sub-structure with embedded defect

Aim and objectives

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Modelling of CFRP spar with wrinkle defect

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Thermoelastic stress analysis (TSA)

( )1 1 2 2p

TTC

= +

Provides a stress metric

TSA uses lock-in processing to extract T from a noisy signal

Digital Image Correlation (DIC)Uses surface contrast to track displacements between two images to provide the component strains x, y and xy

Lock-in DIC (LIDIC)Uses lock-in processing to extract strains during cyclic loading so DIC and TSA are performed simultaneously to provide x, yand xy and T

Fruehmann, R.K., Dulieu-Barton, J.M., Quinn, S., and Tyler, J.P., Digital image correlation applied to cyclically loaded components, Optics and Lasers in Engineering. 2015.

Experimental technique

19

The test component

300 mm

Edge treatment

Centre regionEdge region

Outer corner

Inner corner

Surface preparation: thin layer of matt black paint for TSAFine white speckle for DIC (~6 speckles per mm)

T.A. Fletcher et al., Resin treatment of free edges to aid certification of through thickness laminate strength. Composite Structures 146 (2016) 26-33

20

Loading test rig in test machine

Composite structural component

Series of bearings to isolate bending moment transfer to hydraulic actuator

Applied tensile load

300 mm

Provide stress state at corner

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Wing spar loading

23

Results

Subsurface winkle & delaminations

X-ray CT scan after failure, 3D rendering: centre location

Surface region on TSA and LIDIC for comparison

Stress concentrations and initiation of delaminations

Strain concentrations

24

24

TSA and LIDIC comparison: after first (20kN) load

Wrinkle detected in both TSA and LIDIC

Mean load: 10 kN; Amplitude: 5 kN; 5 Hz

25

TSA: Inner corner after 1st, 2nd, 3rd and 4th load (delamination failure at 45 kN)

After 1st load

After 4th load

After 2nd load

After 3rd load

Initial delaminations

26

After 1st load

After 4th load

After 2nd load

After 3rd load

yy after load steps 1-4 inner surface of specimen

27

yy immediately prior to load drop 44.1 kN

Static yy strains

28

Chart1

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Strain profile

Position (px)

eyy strain

Sheet1

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towards a new paradigm for high- fidelity … · multi-scale modelling of composite substructures...

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