Analysis of Fastener Disbond/ Delamination Arrest Mechanism for Laminated Composite Structures
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1 Analysis of Fastener Disbond/ Delamination Arrest Mechanism for Laminated Composite Structures Kuen Y. Lin, Eric Cheung, Phillip Gray, and Erik Bruun Department of Aeronautics and Astronautics University of Washington November 1 st, 2011
2 FAA Sponsored Project Information Principal Investigator: Dr. Kuen Y. Lin, Aeronautics and Astronautics, UW PhD Student: Chi Ho Eric Cheung, UW Graduate Research Assistant: Phillip Gray, Erik Bruun, UW FAA Personnel: Lynn Pham, Larry Ilcewicz, Curtis Davies Industry Participants: Marc Piehl (Boeing Project Manager), Gerald Mabson, Eric Cregger, Matt Dilligan, Doug Frisch (Boeing) Industry Sponsors: The Boeing Company
3 Objectives To understand the effectiveness of delamination/disbond arrest mechanisms Tasks To develop analysis tools for design and optimization 1. Develop Finite Element models in ABAQUS [completed] 2. Develop 1-D (beam) [in progress] analytical solution 3. Develop and conduct validation experiments [in progress] 4. Conduct sensitivity studies on fastener effectiveness and stacking sequence effects [pending] 5. Implement reliability analysis capability [pending]
4 Composite Structures with Fasteners
5 Previously AMTAS Cheung_Fall_2010.pdf Design and FEA of a Novel 3-Plate Crack Propagation Specimen Development of Analytical Solution to the Crack Arrest Problem JAMS fileticket=gd2sszjr360%3d&tabid=123&mid= Analytical Solution to the 3-Plate Crack Propagation Specimen 2. Effect of Fastener Hole Clearance 3. Early Testing of the 3-Plate Crack Propagation Specimen
6 3-Plate Specimen Description 3 x 24-ply quasi-isotropic laminate with crack at fabric/ fabric interface; secondary bonding 3 x 24-ply quasi-isotropic laminate with crack at 0/0 interface; co-cured 0.25 Titanium fastener installed at half installation toque: 40 in-lb Initial cracks are implanted with Teflon inserts 1.5 from the fastener 6
7 Secondary Bonded Specimens Crack initiation is immediately followed by ultimate failure Filled/Open-hole tension failure of the outer laminates Crack propagation load > ultimate load in tension Crack jumps from the bondline to a couple plies into the outer laminates Fracture toughness of the secondary bond is too high 7
8 Secondary Bonded Specimens Fastener Installed Initiation Load (kip) Ultimate Failure Load (kip) Propagation Mode Ultimate Failure Mode 1 Yes Disbond w/ Bridging Net-section Failure 2 (Pre-Crack) Yes Disbond w/ Bridging Net-section Failure 3 Yes Disbond w/ Bridging Net-section Failure 4 Yes Disbond w/ Bridging Net-section Failure 5 No Disbond w/ Bridging Net-section Failure 6 Yes Disbond w/ Bridging Net-section Failure 7 Yes Disbond w/ Bridging Net-section Failure 8 No Disbond w/ Bridging Net-section Failure
9 Secondary Bonded Specimens
10 Co-Cured Specimens Crack initiation load occurs at ~20.6 kip Initial crack growth is stable Fastener with significant installation torque could have stabilized crack propagation Cracks reach fastener at ~23.6 kip Crack front stays at 0 / 0 interface Ultimate failure occurs at ~30.4 kip Filled hole tensile failure of outer laminates Minor crack growth (V-shape) detected around the fastener
11 Co-Cured Specimens Initiation Load Crack Reaches Fastener Crack location at Test-end (NDI) Crack front shape at Testend Test-end load Tested to Ult. Failure kip 23.2 kip 1.1 in Straight 30.4 kip Yes kip 25.1 kip 0.5 to 1.1 in Straight, but at an angle 29.7 kip Yes kip 23.6 kip 0.6 in V-shape 29.5 kip No kip 24.3 kip 0.6 in V-shape 29.3 kip No
12 Future of the 3-Plate Specimen Competing failure mode is a major hurdle The fastener definitively arrested the crack, but unable to determine the maximum capability Specimen can be optimized for higher G II available Increase stiffness of the center plate; decrease stiffness of outer plate Increase total thickness But loses flexibility in choosing lay-up G IIC could be reduced by using a different material system or manufacturing technique Arrest capability could be reduced by using a smaller fastener and reducing the installation torque
13 2-Plate Specimen Description BMS unidirectional pre-preg tape BMS peel ply Titanium Fasteners (0/45/90/-45) 3S (0/-45/02/90/45/02/-45/90 /45/0) S Ashley, Curtis (MSE)
14 2-Plate Specimen Photo Collage
15 Manufacturing Issues
16
17 ATP 2
18 ATP 3
19
20 2-Plate Specimen Summary Fastener install torque (friction) is a major driver of crack arrest capability High-stiffness lay-up experience more increase in arrest capability for the same fastener size and torque Fabrication issues persist Use heat press Crack propagation is not symmetric across the width of the specimen, especially near the fastener
21 Future Work 3-Plate Specimen Optimize thickness and lay-up Pre-cracking 2-Plate Specimen Improve manufacturing quality Different thicknesses and lay-ups Different fastener sizes Analytical solution
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