MSC NASTRAN Patran Progressive Failure and Delam 021712

SECTION 3 Progressive Ply Failure and Delamination Modeling
Composites Technology Day, January February2012 2012

Copyright 2012 MSC.Software Corporation S3 - 1
Composites Failure Modeling

Look at types of problems you can solve today with MSCs composite failure technology
Examples demonstrating how to apply this technology and how it works
Composites Technology Day, January 2012 Copyright 2012 MSC.Software Corporation S3 - 2
Composite Fuselage Example

Composite aircraft fuselage
Light weight composite components Constructed from layered composite material Bonded and/or fastened together
Composites Technology Day, February 2012 Copyright 2012 MSC.Software Corporation
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A Closer Look
Simulate delamination?
Stringers
Frame
Shear clips
Skin
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Composites Damage and Manufacturing Defect Examples
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Composites Failure Examples
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First-Ply-Failure Analysis
First-Ply Failure (FPF)
Linear analysis based on failure theory Compute failure index or strength ratio for the ply material Optimization of ply angle/thickness
Critical Margin of Safety
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Going Beyond FPF

Evaluate the load redistribution in a composite structure as the plies fail progressively Simulate delamination growth from initial flaw Study crack propagation to design for fail-safe structures
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Going Beyond FPF

Ply Material Failure Delamination
VCCT
CZM
PFA Delamination
Breaking Glue
FAQ: What Element types are supported?

Composite failure modeling is supported in both shell and solid elements Shell element
Solid element
Solid Shell element
Layered Composite definition
Composites Failure Modeling - PFA
VCCT
CZM
11
Breaking Glue
PFA
Delamination
Progressive Failure Analysis (PFA)

Also known as Progressive Ply Failure (PPF) Select a failure criterion Select a degradation option The composite is failed on a layer by layer basis Upon failure, the elastic properties are scaled down
Pin bearing on hole

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Composite Failure Criteria

Composite Failure
Most of the criteria are semi-empirical in nature
Composite Failure on Layer Basis

Maximum Stress Maximum Strain Hill Hoffman Tsai-Wu Hashin Puck Hashin-Tape Hashin-Fabric User defined (UFAIL)
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PFA Options
Progressive Composite Failure options
Flagged through the MATF entry (ITYPE = 2 or 3)
Up to three failure criteria can be selected

Only the primary failure criterion is used for PFA The other two are only used to calculate failure indices The behavior up to the failure point is linear elastic Upon failure When failure index is larger than one, degrade material moduli Selective degradation if matrix fails, do not change fiber properties Stiffness drops gradually or immediately
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MSC Nastran Input Data Format
ITYPE: 0 No PFA; 2 Gradual Selective; 3 Immediate Selective
Criterion: 1 Max. Stress; 2 Max. Strain; 3 Hill; 4 Hoffman; 5 Tsai-Wu; 7 Hashin; 8 Puck; 10 Hashin-Tape;11 HashinFabric; 13 User Subroutine
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PFA Example Fuselage Damage

Rigid elliptical cylinder hitting composite shell
5-layered composite Puck criterion, gradual option Damage of outer ply
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PFA Example Wing Damage
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Micromechanical Failure model

Traditional approach computes composites failure based on ply-level failure properties
The Micromechanical approach gets down to the fiber and matrix level and looks at the failure mechanism at the constituent level MSC has partnered with Firehole to bring the Helius MCT micromechanical failure technology to our users
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Composites Failure Modeling - VCCT
VCCT
CZM
19
Breaking Glue
PFA
Delamination
VCCT
In linear fracture mechanics, a crack starts to grow when
Total G > Gc G is the energy release rate Gc is the fracture toughness
The VCCT is one of the methods used to compute the energy release rate.
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VCCT (Virtual Crack Closure Technique)
FEM approximation: Use consistent nodal force at

tip and crack opening at first crack segment Energy release rate: G = Fu/2a Growth method Release glued contact Grow along element edge Marc Only Remeshing
VCCT
Supported in both Marc and MSC Nastran Supported crack types are shown below
line crack 2D or shell
face crack shell to shell
face crack 3D solid
line crack shell edge to solid or shell

face crack shell to solid
Modes of Crack Extension

All three modes of crack extension are supported
Mode I: Opening
Mode II: Sliding

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Mode III: Tearing
VCCT Example Release glued contact

Skin-Stringer Delamination
Wagner/Balzani, Computers & Structures 2008 Stringer glued to skin
stringer
initial crack front Initial delamination
skin
fixed stringer VCCT key ingredients: - Initial crack Composites Technology Day, February 2012 - Define crack front nodes
Copyright 2012 MSC.Software Corporation S3-24
push skin downward
Animation shows glued region
Animation shows region released from glued
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Benchmark Problems
DCB
DCB
SLB
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DCB

4-Ply Composite modeled with 2 layers of solid elements Defect between 3rd and 4th ply Glue parts together, except at defect F Buckling Delamination
Embedded circular defect
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VCCT Example Grow Along Element Edge

Growth direction: maximum hoop stress criterion
Initial crack
clamped
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VCCT Example Grow Along Element Edge
Quad mesh
Tria mesh
Remesh
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VCCT Example Crack Bifurcation

New technology
Crack tip automatically generated as the crack reaches the stiffener
8 layers 4 layers glued
shell thickness with offsets
elastic orthotropic material composite with four layers: [-45/90/0/45]
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Growth through composite skin with stiffeners
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Courtesy of Dr. Kim Parnell

Composites Failure Modeling - CZM
VCCT
CZM
34
Breaking Glue
PFA
Delamination
Cohesive Zone Modeling (CZM)

Cohesive Zone Modeling (CZM) is a technique
used to simulate delamination growth.
The implementation of CZM is based on:

Library of special interface elements Material model to characterize the interface behavior
Interface Element
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The constitutive behavior of these elements is expressed in terms of tractions versus relative displacements between the top and bottom edge/surface of the elements
Top and bottom faces may coincide
V is the effective opening displacement
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Material models
Bilinear Exponential Linear-exponential
8 4 n 5 1 top face
t
6
2
top and bottom face may coincide (zero thickness) 3 bottom face
Material behavior
Initially reversible Irreversible if v > vc
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CZM Example
Lap-Shear Joint:
Plates
Adhesive Region
Reference: M.N. Cavalli, M.D. Thouless and Q.D. Yang, Cohesive-Zone Modeling of the Deformation and Fracture of Weld-Bonded Joints; Welding Journal Vol. 83, no. 4, 2004
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CZM Example
Finite element model:
Mesh plates and adhesive layer independently using higher order elements Utilize the contact option to glue the adhesive layer to the plates
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CZM Example
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Composites Failure Modeling Breaking Glue Contact
CZM VCCT
41
Breaking Glue
PFA
Delamination
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Breaking Glued Contact

Release glued contact when the following stress criterion is met
User specified
User specified
Use contact normal and tangential stresses After break, do regular contact with friction and separation
Example - Breaking glued contact

Coating debonding Load with rigid body
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Example - Breaking glued contact

Coating debonding Load with rigid body
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Composites Failure Modeling Delamination (Marc only)
CZM
VCCT
45
Breaking Glue
PFA
Delamination
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Delamination
Split up mesh between materials or within a material when the following stress criterion is met
Use stresses normal and tangential to interface
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Delamination Examples
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Delamination with CZM

Option to insert interface element where mesh is split
Fully automatic
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Delamination Example: Plate impact

Composite plate, 8 layers, [0/45/45/90]s Stacked solid shell elements
One element per layer No double nodes
Clamped edges, prescribed downward motion of circular region in the center
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View quarter model Outline plot Delamination between layers (mesh splitting) Contact occurs between layers
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Automatic insertion of interface elements Self contact not needed Show only interface elements
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Summary
Progressive Failure Analysis (PFA) Virtual Crack Closure Technique (VCCT)
Fracture mechanics
Cohesive Zone Model (CZM)

Interface elements
Breaking glued contact

Stress Criterion
52
Delamination
Stress Criterion
End of Section 3
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MSC NASTRAN Patran Progressive Failure and Delam 021712

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SECTION 3 Progressive Ply Failure and Delamination Modeling

Composites Technology Day, January February2012 2012

Composites Failure Modeling

Composites Technology Day, January 2012 Copyright 2012 MSC.Software Corporation S3 - 2

Composite Fuselage Example

Composites Technology Day, February 2012 Copyright 2012 MSC.Software Corporation

Composites Damage and Manufacturing Defect Examples

Composites Technology Day, February 2012 Copyright 2012 MSC.Software Corporation

Composites Failure Examples

Composites Technology Day, February 2012 Copyright 2012 MSC.Software Corporation

Critical Margin of Safety

Composites Technology Day, February 2012 Copyright 2012 MSC.Software Corporation

Going Beyond FPF

Composites Technology Day, February 2012 Copyright 2012 MSC.Software Corporation

Going Beyond FPF

FAQ: What Element types are supported?

Layered Composite definition

Composites Failure Modeling - PFA

Progressive Failure Analysis (PFA)

Pin bearing on hole

Composite Failure Criteria

Composite Failure on Layer Basis

Composites Technology Day, February 2012 Copyright 2012 MSC.Software Corporation

Up to three failure criteria can be selected

Composites Technology Day, February 2012 Copyright 2012 MSC.Software Corporation

MSC Nastran Input Data Format

ITYPE: 0 No PFA; 2 Gradual Selective; 3 Immediate Selective

Composites Technology Day, February 2012 Copyright 2012 MSC.Software Corporation

PFA Example Fuselage Damage

Composites Technology Day, February 2012 Copyright 2012 MSC.Software Corporation

PFA Example Wing Damage

Composites Technology Day, February 2012 Copyright 2012 MSC.Software Corporation

Micromechanical Failure model

Composites Technology Day, February 2012 Copyright 2012 MSC.Software Corporation

Composites Failure Modeling - VCCT

Composites Technology Day, February 2012 Copyright 2012 MSC.Software Corporation

VCCT (Virtual Crack Closure Technique)

FEM approximation: Use consistent nodal force at

line crack 2D or shell

face crack shell to shell

face crack 3D solid

line crack shell edge to solid or shell

face crack shell to solid

Modes of Crack Extension

Mode II: Sliding

Mode III: Tearing

VCCT Example Release glued contact

initial crack front Initial delamination

push skin downward

VCCT Example Release glued contact

Animation shows glued region

Animation shows region released from glued

Composites Technology Day, February 2012 Copyright 2012 MSC.Software Corporation

VCCT Example Release glued contact

Composites Technology Day, February 2012 Copyright 2012 MSC.Software Corporation

VCCT Example Release glued contact

Embedded circular defect

Composites Technology Day, February 2012 Copyright 2012 MSC.Software Corporation

VCCT Example Release glued contact

Composites Technology Day, February 2012 Copyright 2012 MSC.Software Corporation

VCCT Example Grow Along Element Edge

Composites Technology Day, February 2012 Copyright 2012 MSC.Software Corporation

VCCT Example Grow Along Element Edge