16th International Conference on Composite Structures

(ICCS16)
Analysis of Crushing Response of Composite
Crashworthy Structures
Matthew David and Alastair Johnson
DLR Institute of Structures and Design, Stuttgart
16th International Conference on Composite Structures , ICCS 16
Analysis of Crushing Response of Composite Crashworthy Structures
M. David & A. Johnson
Slide 2
Overview
Introduction
Experimental Investigation (Strain rate)
Testing and Analysis Methodology
Identification of varied crush response modes
Experimental Investigation (Stacking sequence)
Conclusion
Outlook
16th International Conference on Composite Structures , ICCS 16
Analysis of Crushing Response of Composite Crashworthy Structures
M. David & A. Johnson
Slide 3
Introduction
Crashworthy structures
During a crash scenario, the role of a crashworthy structure is to utilize energy absorbing
mechanisms to absorb crash loads in a controlled progressive manner.
Goals of a crashworthy structure are: 1. Limit deceleration on occupants
2. Allow the safe evacuation of occupants by
maintaining sufficient structural integrity
Full scale drop test conducted at CIRA (HeliSafe TA)
Bell UH-1D fitted with 3 dummies
Impact conditions (Vx = 11.1 m/s
2
, Vz = 9.3 m/s
2
)
16th International Conference on Composite Structures , ICCS 16
Analysis of Crushing Response of Composite Crashworthy Structures
M. David & A. Johnson
Slide 4
Introduction
Motivation
Cooperation between CRC-ACS & DLR Crashworthy Design (2007-2010)
Concepts for helicopter subfloor structures with improved energy absorption
Numerical design tools for predicting crash response of composite aircraft structures
Stiff Survival
space
Energy absorbing
structure
Drop tower test of a crashworthy structure
(C. Kindervater et al., 2011)
16th International Conference on Composite Structures , ICCS 16
Analysis of Crushing Response of Composite Crashworthy Structures
M. David & A. Johnson
Slide 5
Introduction
Energy absorbing coupon specimen
Developed to understand the energy absorption and failure mechanisms of energy absorbing
structures at an coupon level
Easy to fabricate and gives reproducible axial crush failures under quasi-static and dynamic
loading conditions
Sub-floor box structure
(CRASURV)
Coupon specimen
16th International Conference on Composite Structures , ICCS 16
Analysis of Crushing Response of Composite Crashworthy Structures
M. David & A. Johnson
Slide 6
Experimental Investigation Strain rate
Methodology
Test Methodology
Crush load curves extracted from test machines
Video and still images of crushing process and specimens
High Resolution Computed Tomography (HRCT) scan
Analysis Methodology
Quasi-static crush test at a cross head velocity of 1.0 mm/s
Dynamic crush test at an impact velocity of 10.0 m/s
Dynamic crush test setup
Loading
platen
16th International Conference on Composite Structures , ICCS 16
Analysis of Crushing Response of Composite Crashworthy Structures
M. David & A. Johnson
Slide 7
Experimental Investigation Strain rate
Test specimen specifications
Material : Hexply M18/1/43%/G939/1230 five harness fabric pre-peg material system
Ply Layup : [(0/90)
2
/0/(90/0)
2
] configuration
Trigger Mechanism : 45 outside chamfer
Sketch of specimen Specimen affixed in clamp
16th International Conference on Composite Structures , ICCS 16
Analysis of Crushing Response of Composite Crashworthy Structures
M. David & A. Johnson
Slide 8
Experimental Investigation Strain rate
Crushing process
Quasi-static
Dynamic
16th International Conference on Composite Structures , ICCS 16
Analysis of Crushing Response of Composite Crashworthy Structures
M. David & A. Johnson
Slide 9
Experimental Investigation Strain rate
High-Resolution Computed Tomography (HRCT)
Non destructive analysis (NDT)
Nanotom CT system by phoenix xray
Acquisition phase (2-D) to the reconstruction of the volumetric data (3-D) took ca. 5 hours
Voxel resolution of 7 microns
HRCT-scan image slices
Detailed analysis of cross section
16th International Conference on Composite Structures , ICCS 16
Analysis of Crushing Response of Composite Crashworthy Structures
M. David & A. Johnson
Slide 10
Experimental Investigation Strain rate
HRCT-scan image of crushed coupon specimen
Quasi-static loading condition Dynamic loading condition
16th International Conference on Composite Structures , ICCS 16
Analysis of Crushing Response of Composite Crashworthy Structures
M. David & A. Johnson
Slide 11
Experimental Investigation Strain rate
Energy absorption performance parameters
Typical force-displacement curve
(progressive failure mode)
Crush force efficiency (CE) :
Peak Crush Force / SSCF
Energy Absorbed (EA) :
Area under Crush Force-Displacement
curve
Specific Energy Absorbed (SEA) :
EA / Mass of crushed portion
16th International Conference on Composite Structures , ICCS 16
Analysis of Crushing Response of Composite Crashworthy Structures
M. David & A. Johnson
Slide 12
Experimental Investigation Strain rate
Energy absorption comparison
16th International Conference on Composite Structures , ICCS 16
Analysis of Crushing Response of Composite Crashworthy Structures
M. David & A. Johnson
Slide 13
Experimental Investigation Strain rate
Varied crush response
Inter and intra molecular interaction during the load bearing phase
Quasi-static loading condition
Dynamic loading condition
Inter molecular interactions between polymer chains only due to time scale of the test
Difference attributed to the strain rate dependency of the epoxy resin :
where the time scale of the load bearing phase dictates the extent of changes in the polymer
chains
Brittle Behavior
Ductile Behavior
16th International Conference on Composite Structures , ICCS 16
Analysis of Crushing Response of Composite Crashworthy Structures
M. David & A. Johnson
Slide 14
Experimental Investigation Strain rate
Dynamic material properties (carbon-epoxy)
Tensile stress-strain curve
Shear stress-strain curve
(K.S Raju et al. 2011)
16th International Conference on Composite Structures , ICCS 16
Analysis of Crushing Response of Composite Crashworthy Structures
M. David & A. Johnson
Slide 15
Experimental Investigation Strain rate
Summary of varied crush response
Global splaying failure crush mode
Local fragmentation failure crush mode
16th International Conference on Composite Structures , ICCS 16
Analysis of Crushing Response of Composite Crashworthy Structures
M. David & A. Johnson
Slide 16
Experimental Investigation Stacking sequence
Test specimen specifications and methodology
Material : ACG MTM44-1FR/468 four harness fabric pre-preg material system
Ply Layup : [(0/90)
2
]
s
configuration
[(+45)
2
]
s
configuration
Test methodology : Dynamic crush test at an impact velocity of 10.0 m/s
Analysis methodology : As previously described
16th International Conference on Composite Structures , ICCS 16
Analysis of Crushing Response of Composite Crashworthy Structures
M. David & A. Johnson
Slide 17
Experimental Investigation Stacking sequence
Crushing process
Quasi-static
Dynamic
16th International Conference on Composite Structures , ICCS 16
Analysis of Crushing Response of Composite Crashworthy Structures
M. David & A. Johnson
Slide 18
Experimental Investigation Stacking sequence
Energy absorption comparison
16th International Conference on Composite Structures , ICCS 16
Analysis of Crushing Response of Composite Crashworthy Structures
M. David & A. Johnson
Slide 19
Conclusion
Successful experimental methodology implemented in testing and analysis of crush coupon
specimens
Identification and detailed study of varied crushing response and failure modes
(Global and Local) from increasing compression strain rates
Importance of understanding the role of strain rate dependency in the design of crashworthy
structures highlighted from the work presented
Future outlook includes the adoption of the experimental methodology to study the crush
response of crush coupons consisting of varied:
Dynamic loading rates
Geometries
Material systems
16th International Conference on Composite Structures , ICCS 16
Analysis of Crushing Response of Composite Crashworthy Structures
M. David & A. Johnson
Slide 20
Acknowledgements
The authors would like to thank CRC-ACS for the supply of specimens, valuable
discussions and exchanges throughout the collaboration.
16th International Conference on Composite Structures
(ICCS16)
Analysis of Crushing Response of Composite
Crashworthy Structures
Matthew David and Alastair Johnson
DLR Institute of Structures and Design, Stuttgart