impact analysis of aluminum-fiber composite lamina unidirectional fiber composites will be...
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[溶接学会論文集 第 33 巻 第 ○ 号 p. 000s-000s(2015)]
Impact Analysis of Aluminum-Fiber Composite Lamina*
by Yehia Abdel-Nasser**, Ninshu Ma***, Hidekazu Murakawa*** and Islam El-Malah**
Hybrid materials of fiber composite and aluminum alloys have a great potential in reducing the weight of transportation vehicles. It has been become an alternative solution to steel panels because they can provide high strength and improve energy absorbing capability under impact and collision loading. Developing a new composite material based on experiment by changing mechanical properties is quite expensive and takes long time. Therefore, numerical simulation with the aid of FEM is often performed, since its results have been proved to be close to the experimental ones. There are many different ways to combine the fiber into the resin. In this paper, the effect of lining arrangements of composite materials and the orientations of the layers on the strength was simulated using FEM in which the adhesive bond between fiber composite/metal is assumed as a tie constraint. Impact strength and failure modes of several plate panels with different lining arrangements were investigated. The results of analyses are presented and their trends are discussed.
Key Words: FEM, Hybrid Plate Panels, Lining Arrangements, Impact Analysis, Penetrations
1. Introduction
A composite material is fabricated by combining two or more
distinct materials together but remaining uniquely identifiable in
the mixture. The most common example is, a fiberglass
composite material, in which glass fibers are mixed with a
polymeric resin1). Composite materials are becoming increasingly
more attractive in a variety of structural engineering applications,
such as airplane fuselages, turbine blades, patrol boats and car
bodies. The challenge at hand is to use a composite material that
is optimized to provide the same or better strength and stiffness as
that of traditional isotropic materials. The amount of fracture load
at which a piece of fiber glass breaks, depends on the size of the
piece of fiberglass, its thickness, width, length, and also the
loading direction 2). It also depends on what the fiberglass is made
of such as layers orientations of fibers and amount of polymeric
resins. The goal of this paper is to analyse the strength of hull
structures made of composite materials as an alternative solution
to replace the heavy steel structure. It is anticipated that the use of
the composites will save on overall weight in order to maximize
potential payload capacity. The optimal composite design is
expected to be both lighter than the steel configuration, and
exhibited resistance to more severe loading conditions such as
impact loadings3). It is possible to design a composite material
such that it has the attributes desired for a specific application.
For example, fiber-Metal Laminates (FMLs) are a hybrid of metal
and composite laminates that are increasingly being used in
aerospace structures4). This is consisting of alternating layers of
thin metallic sheets and fiber-reinforced epoxy. Two main types
of FML are aramid fiber-reinforced epoxy /aluminum laminates
(ARALL) and S2 glass fiber-reinforced epoxy/aluminum
laminates (GLARE). The combination of mechanical properties
of monolithic metal and fiber-reinforced composite provides
FMLs with mechanical advantages such as low density, high
strength, and high damage tolerance. Impact damage is a key
concern for the safety of transportation vehicles5). Therefore it is
necessary to accurately predict internal impact damage to FMLs
and other composite materials6). Therefore, the goal of this
project is to rearrange lay-up of aluminum-fiber composite
lamina through changing mechanical properties and lining
arrangements of the layers, and comparing results of the
arrangements to obtain higher performance of the plate lamina
against impact and blast loadings. These changes can be virtually
done by numerical simulation using FEM-software such as
“ABAQUS”7). However, the numerical results required to be
verified through laboratory experiments.
2. Failure criteria
The failure of a composite panel will be resulted from either a critical strain or stress exceeded in the matrix or fiber. The composite behaves elastically and reaches to the point of failure, primarily because the glass fibers and the polymeric resin were both linear elastic solids with a brittle fracture mode, i.e., no
*Received: 2014.11.28 **Faculty of Engineering, Alexandria University ***Member, Joining and Welding Research Institute, Osaka
University
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plastic deformation. We would also note from the mechanical tests that the elastic modulus of the composite also varied with the amount of fiber added to the resin. Hashin’s failure criteria8) for Unidirectional Fiber Composites will be considered in this work. These are interacting failure criteria where more than one stress components have been used to evaluate the different failure modes. Usually Hashin criteria are implemented within two dimensional classical lamination approach for stress calculations with ply discounting as the material degradation model. After that, he extended the criteria to three dimensional problems where the maximum stress criteria are used for transverse normal stress component.
3. Description of FE models
The paper addresses the numerical simulation of impacts on
plate panels by applying FEM. The plate panels are composed
from hybrid material (S2 glass fiber-reinforced epoxy/ aluminum
laminates). The research work is aimed to optimize the
arrangement of composite layers which sustained the maximum
impact load. Other loads such as in-plane loads are not considered
here. The FE simulation of the impact analysis encompasses a
number of individual problems such as mesh size, element type
and time increments, which should be given appropriate attention
during the analysis. In the analysis, a fine mesh is generated
especially at the contact areas (mesh size=3x3x0.5mm) to acquire
accurate results and to represent real failure modes during impact.
Whereas coarse mesh may be applied for areas located far from
collision region to reduce CPU time. Also appropriate element
type (8 node break element) is selected to achieve accurately FE
analysis and increase the reliability of numerical models. The
adhesive bond between the glass/epoxy plies and aluminum
layers was modeled using the tie constraint module in Abaqus
software to express the delaminating failure. Abaqus/Explicit can
be applied to model nonlinear material behavior in a composite
laminate. Other problem such as modeling of the material damage
criteria is explained in Refs.9).
Abaqus/Explicit version is used to simulate the impact of plate
panels with a striking object such as ball or cylinder at different
velocity. The plate panels are modeled using solid elements
(C3D8R). The impactor (ball or cylinder) is modeled using rigid
elements (R3D4). This assumption is chosen because we are
interested in comparing the effect of the impact on the different
plate panels with no reference to the impactor. Different
configurations of lining arrangement are investigated. The
absorbed energy and contact force for each arrangement of the
plate panel are calculated after damage. The following
assumptions are considered in the models:
Volumetric ratio of composite (fiber/resin) is 50%.
The plies are symmetric laminated composites.
Unidirectional fiber or Random fiber is assumed.
Adhesive bond between Fiber/Metal is assumed as a tie
constraint.
4. Validation of FE models
Wu10) conducted a series of low velocity impact tests to evaluate the deformation and damage responses of FMLs. A comparative study is conducted using these experimental impact results to validate a basic numerical model. The model consists of two layers of Al 2024-T3 Aluminum alloy sheets and one layer of [0/90/90/0] S2 glass/epoxy composite. Here, Al is referred to the material of aluminum and /0/90/90/0/ is referred to 4plys of the composite material as shown in Fig.1. A steel spherical impactor of 12.3 mm diameter and with a mass of 6.29 kg impacted the plate panel with different impact energies such as 12.7J, 16.3J and 24.3J respectively. The hybrid plate panel (Aluminum-Fiber composite) of (0.076x0.076m) with total plate thickness 1.56mm is analyzed using FEM. The plate panel is clamped at all edges. The mechanical properties of S2 glass/epoxy4) are as shown in Table 1. The Aluminum 2024-T3 is assumed to be an elastic material and its characteristics are as follows: Young’s Modulus E= 73800 MPa and Poisson’s ratio ʋ=0.33. Hashin failure criteria are applied to trace the failure state of the composite material while the ductile failure criterion is applied for the aluminum. The tie constrained law is applied to express the adhesive bond between fiber composite and aluminum7). The time of impact is taken about 6 x10-3second.
Table 1 Mechanical properties of S2 glass/epoxy.
Material Parameter values (GPa)S2 glass/ epoxy
E11 E22 E33 G12 G23 V12 V23
55 9.5 9.5 5.5 3 0.33 0.33
Parameter values (MPa)
σLU,t σLU,c σTU,t σTU,c τLT u
2430 2000 50 160 50
The mesh model of the plate panel and the impactor are shown
in Fig.2. The impactor is moving with a constant velocity towards
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the plate panel. The numerical results show that the maximum
deformation is observed at the center of the plate panel. Figure 3
shows relationships between contact force and time for different
levels of energy. At low energy such as 12.7J the numerical
results have the same value in the contact force curve when
compared with the experimental results. However, for 16.3J and
22.3J energy, at the elastic state the same results are attained but
the deviations are observed after damage. Here, the numerical
results show higher contact forces than those attained by the
experimental ones. This is because the debonding of the
Aluminum layers and the composite layer was constrained using
the tied constraint. During the impact analysis of the plate panel,
failure modes such as plastic deformation of the metal layers
(Aluminum) and matrix cracking and fiber failure of the
composite layer are observed. Figure 4 shows relationship
between deflection at the center of the plate panel and the time.
The central deflection is reached to about 4.5mm and it is
increased as the impact energy increases. The effect of fiber
dimensions and orientations are not considered in this study11).
5. The impact behavior
In this section, the hybrid plate panel of 0.5x0.5m is modeled
with solid elements. The cylinder is modeled with 3D rigid
elements. The cylinder is moving towards the center of palate
panel with a high energy of about 2000J. The dynamic explicit
solver was used to account for the time-dependent loading and
the complex interaction between the cylinder and the composite
plate panel. The model with different arrangements of fiber glass
and Aluminum laminated layers are investigated to determine the
best arrangement that able to prevent cylinder penetration and
absorb the high energy (2000J). These model arrangements are
suggested as follows, (See Fig.5)
3GL (3 layers of Aluminum each layer has 4 mm thick and 2
layers of fiber glass/epoxy each layer has 3mm thick).
4GL (4 layers of Aluminum each layer has 3 mm thick and 3
layers of fiber glass/epoxy each layer has 2mm thick).
5GL (5 layers of Aluminum each layer has 2 mm thick and 4
layers of fiber glass/epoxy each layer has 2mm thick).
Each layer of the composite material is consisted of 4 plies
Fig. 1 The hybrid plate panel. Fig. 2 Mesh model of the hybrid plate panel.
Fig. 3 Relationships between the impact force and time. Fig. 4 Relationships between the deflection and time.
Rigid ball
Fiber layers
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with equal ply thickness and unidirectional of the stack sequences
(0/90/0/90). The local co-ordinate systems are defined to account
for orientations of individual plies and to model the laminate and
material behavior precisely. The material properties of the
composite are given in Table 1. While properties for Aluminum
are taken from Ref12). The cylinder of mass 8g and length 39 mm
impacts the center of the plate panel in the axial direction with a
constant velocity of 700m/s as shown in Table 213). Here, due to
the high energy, the time of impact is taken about 12x10-5 second.
Table 2 Characteristics properties of the cylinder 13).
Designation Weight g
Velocity m/s
EnergyJ
7.62x39mm 8 700 2000
The developed FE model is shown in Fig. 6. Fine mesh is
generated at the center of the plate panel.
Figure 7 shows the penetration of the cylinder into the plate
panel. It is noticed that for 3GL and 4GL arrangements, after the
plastic deformation spreads at the center of the face layer (Al) of
the plate, failure starts at the face layer (Al) then the cylinder
penetrates the face (Al) layer and reaches the composite layers
causing brittle damages in its plys. Finally, the cylinder penetrates
the second layer (Al) of the plate panel after causing large
deformation in this layer (Al). This process is repeated for
remaining layers of the plate panel. Figure 8 shows the ductile
fracture of aluminum layers and brittle fracture of the composite
layers. Figure 9 shows relationships between moving velocity of
the cylinder and time. At the beginning, the cylinder is moving
with a velocity of 700m/s, then its velocity gradually decreases.
For 3GL model, the cylinder penetrates the plate panel at time of
5.2x10-5 second and it still has a kinetic energy with a velocity of
about 138m/s. At the end a complete penetration is occurred.
Regarding 4GL model, the cylinder penetrates the plate panel at
time 6.1x10-5 second and its kinetic energy is gradually dissipated
with final zero velocity. For 5GL model, the cylinder could not
penetrate the plate panel. It approaches zero velocity and totally
lost its ballistic energy. It is noticed that with increasing number
of (Al) layers as in cases 4GL and 5GL arrangements; the
velocity of the cylinder is drastically decelerated. Table 3 shows a
comparative analysis for the previous arrangement using the
specified material properties.
In this analysis, the weight parameter defined by the weight per
area WP (kg/m2) of the plate panel is a little bit high. The weight
parameter WP (kg/m2) may be reduced by utilizing higher
strength of composite materials to get less plate thickness13). It
can be safely assumed that at high loading rates, as normally
observed in ballistics impact, the metal layers and glass fibers
undergo considerable hardening before failure thus providing
extended resistance.
Table 3 Characteristics of plate panel arrangements during
analysis.
Model Arrangement
Plate Thick(mm)
Time of penetration
(s)
Weight (kg /m2)
Failure of layers
End Velocity
(m/s)
3GL 18 5.2x10-5 44.4 All 138
4GL 18 6.1x10-5 44.4 Not All 0
5GL 18 Not 43 Not All 0
Fig. 6 Mesh model of the plate panel before and after penetration.
Fig. 7 Penetration of the cylinder into plate panel arrangements.
3GL 4GL
5GL Fig. 5 Different arrangements of hybrid plate panels.
Al Fiber
Penetration
Rigid Cylinder
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6. Conclusions
The paper refers to the simulation impact of
aluminum-fiber composite plate lamina using FEM which
provided close results compared with the experimental ones.
It is found that by increasing number of (Al) layers in the
lay-up arrangement of the hybrid plate lamina will
drastically decelerate the velocity of the impacted cylinder
and absorb higher impact energy (2000J). However, higher
weight parameter WP (43kg/m2) of the hybrid plate lamina is
attained. This may be reduced by utilizing higher strength
composite materials to get less plate thickness and weight.
Reference
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11) P. Kumrungsie, K. Maneeratana and N. Chollacoop : Effects of Fiber Orientation on Ballistic Impact upon Polymer Composite Plate, The 21st Conference of Mechanical Engineering Network of Thailand 17-19 (October 2007), Chonburi, Thailand.
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Fig. 9 Relationships between the impact velocity and time.
(a) Ductile damages in Aluminum layers
(b) Brittle damages in composite layers
Fig. 8 Failure damages in the plate panel.
Aluminum
Fiber
170s 研究論文 YEHIA et al.: Impact Analysis of Aluminum-Fiber Composite Lamina