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JOURNAL OF
COMPOSITE
Article M AT E R I A L S
Journal of Composite Materials
0(0) 112
! The Author(s) 2014
Efficient 3D modeling of damage Reprints and permissions:
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in composite materials DOI: 10.1177/0021998314525983
jcm.sagepub.com
Abstract
Due to the complexity of composite material, numerical methods are generally utilized in their analysis and design.
Commercial finite element (FE) codes, such as ANSYS and ABAQUS, allow the implementation of user subroutines in
the program, which provides the advantage of using high meshing and solving technologies besides the improvement of
materials and/or elements models. Nonlinearities arise for many engineering problems, for example, the progressive
damage of a composite element that contains sources of stress concentration or damage localization such as holes, bolts,
and/or flaws causes nonlinear material behavior. In order to simulate this nonlinear behavior, especially in 3D, an accurate
material constitutive model is required. Therefore, the objective of this paper was to simulate the 3D progressive
damage model of composite materials by using simple numerical models. In this paper, ANSYS user subroutine
(USERMAT) was used to simulate the progressive damage behavior of a composite plate containing holes using
simple models. Three different material models were used: ply discount model (PDM), simple progressive damage
model (SPDM) by adding an empirical progressive damage criteria to the PDM, and continuum damage mechanics
model (CDMM). Good agreements were observed between SPDM, CDMM, and published experimental results.
Furthermore, CDMM showed the least dependence on mesh size. Three different damage evolution laws, linear,
quadratic, and degradation laws, were adjusted and tested. It was found that there was no significant difference in the
predicted failure load between these selected laws.
Keywords
3D progressive damage, degradation, composites, finite element, ANSYS, USERMAT
Introduction
With these inputs, either the maximum stress or max-
Laminated ber reinforced polymer (FRP) composite imum strain failure criteria could be used to make rea-
materials are being used in greater frequency mainly sonably accurate predictions of the strength for similar
due to their specic strength and specic stiness tests in the future.14 Under multi-loading conditions,
advantages over conventional materials and since the the prediction of failure becomes more complicated,
ber architecture can be tailored to meet specic design even for homogeneous, isotropic materials. For compo-
considerations. The progressive failure analysis of com- site materials, the tendency for the components of stress
posite laminates is required to predict their mechanical to interact due to the orthotropic material properties
behavior under various loading conditions, and thus and the various failure modes of the constituent
the use of appropriate material constitutive models
plays a crucial role. Continuum damage mechanics
(CDM) provides a physically based concept for simu- 1
Department of Civil and Environmental Engineering, University of
lating damage activation and evolution, which occurs Missouri, Columbia, MO USA
2
in conjugation with stiness reduction.14 Civil Engineering Department, Jazan University, Kingdom of Saudi Arabia
The simplest method for obtaining the stiness and
Corresponding author:
strength properties of a new material is to perform a Hani A Salim, University of Missouri, Columbia, E2509 Lafferre Hall,
direct tensile, compression, and shear tests which will Columbia, MO 65211, USA.
yield the stiness constants and ultimate strengths. Email: SalimH@missouri.edu
materials have led to the development of several other from the three techniques, CDMM shows less depen-
classes of failure criteria as in references.512 dence on mesh size and is capable to capture the 3D
Several works were adopted to analyze the progres- localization.
sive failure of composite materials. The simplest tech-
nique to model degradation of stiness is by applying
an instantaneous degradation factor if the failure cri-
teria are met, which is called the ply discount techni-
Numerical modeling
que.1316 While simple to implement, the sudden, Three simple models were used to simulate the progres-
complete failure of the elements does not compare sive damage in FRP; PDM, SPDM, and CDMM. In
well with experimental observations.13 This technique this section, the three models and their implementations
was followed by a group of models at which damage are described in detail.
state variables associated with the residual stiness of a
lamina were used.1719 The stiness terms of an element
Ply discount model
were degraded according to these internal damage state
variables upon satisfying the corresponding failure cri- This model is the simplest way to model the damage
terion. The aforementioned methods of progressive process; it was used in several previous works.1316 In
damage modeling have led to the development of this model, failure criteria Fm given in Table 1 were
more phenomenal and physically based approaches, checked for the integration points for all elements,
including the damage mechanics approach.2026 where m ft1 for ber tension, c1 for ber
The main objective of this paper was to develop and Compression, t2 for matrix tension, c2 for matrix com-
implement a simple technique for modeling of 3D pro- pression, s12 ber matrix shear, and t3 for thickness
gressive damage in a composite element that contains a direction tension}. For all modes, t1, c1, t2, c2, and
source of stress concentration or damage localization s12, Hashins failure criteria were used. Although the
such as holes, bolts, or cracks. To do this, three simple thickness direction tension is not completely equivalent
models were used to simulate the progressive damage in to delaminating, for simplicity the delamination onset
FRP, which are the ply discount model (PDM), the criterion was used for mode t3.14,16,27 For each integra-
simple progressive damage model (SPDM), and the tion point, if the failure criterion is met, an instanta-
continuum damage mechanics model (CDMM). neous degradation factor (km) is applied to the material
Dierent modeling parameters, such as the mesh size properties at that integration point. The degraded
and the damage evolution laws were studied. The material properties (DMP) for each mode are given in
results of all the proposed models were compared Table 1, and in this model km was taken as 104, where
with experimental test results published in the litera- i is the nominal stress tensor, in which i f1, 2, 3, 12,
ture. Although good correlation could be obtained 23, 13}, and Sm is the lamina strength parameter.
El-Sisi et al. 3
It is important to note that ANSYS 14.528 proposes other for compression mode. For simply adjusting the
three built-in materials that can simulate the damage damage law, a damage activation function (DAF)
initiation and evolution process; the rst one is the based on the maximum strain criteria was used.
MPDG model. In this model, a degradation factor Linear, quadratic, and exponential damage laws were
can be multiplied directly by the material stiness com- used to describe the damage evolution.
ponent if the damage initiation criterion is met. This
model supports 3D solid layered elements, such as Secant stiffness matrix. Six damage variables were
SOLID185 and SOLID186. The second model is adopted to describe the degradation of material proper-
based on damage mechanics, which supports plane ties of di, where i f1, 2, 3, 4, 5, 6}. Among the six
and shell elements only,28 whereas the third model is variables, three independent variables are found, as
a general composite failure model that is available only the damage for shear stiness component is taken
for explicit analysis. Since this paper is mainly focused from the normal damage component, equation (2)
on 3D domain with implicit analysis, MPDG was stu-
died by developing an element test to investigate this d4 1 1 d1 1 d2
material model. It was found that the behavior of this d5 1 1 d2 1 d3 2
material model is a pure ply discount mechanism. d6 1 1 d1 1 d3
The stiness tensor is the relation between the eective state is one of unloading or neutral loading. If the gra-
stress and the strain ", and can be obtained from the dient g_^ m is positive, there is damage evolution, and the
inverse of the 3D compliance tensor, H1 : ". consistency condition has to be satised, i.e.
g_m g_^ m _^ m 0
Damage activation functions. DAF is the function that
denes the elastic domain,3 and it can be dened as .
Under tension loading, the produced cracks do
gm g^m ^m 0 6 not aect the compression response; the compression
elastic domains are unaected by ^m , where
where g^ m is the positive loading function (normal) that m ft1 , t2 , t3 g. The following expressions can be
depends on the stress states, and ^m is the updated used to represent the compression damage thresholds
damage threshold function, and m refers to the failure
mode. The aim of this paper was to develop the sim- ^m max 1, max g^ m 7
plest 3D CDM model and compare it with other simple
models such as PDM and SPDM, and thus a simple where 0 : T, and m fc1 , c2 , c3 g.
loading function was used to describe the damage On the other hand, under compression loading the
initiation process based on the maximum strain cri- produced cracks completely aect the tension response;
teria.14 Table 2 describes the proposed criteria; it can the tension elastic domains are aected by ^m , where
be observed that shear strength was neglected. This was m fc1 , c2 , c3 g (Figure 1). The following expressions
explained in the Secant stiness matrix section since the can be used to represent the tension damage thresholds
degradation of shear stiness components was consid-
ered to be a function of normal stress damage variables ^m max 1, max g^m , g^ n 8
d1, d2, and d3. This means that the activation of damage
in normal stress components would also activate the where 0 : T, m ft1 , t2 , t3 g, and n fc1 , c2 , c3 g.
damage in the shear stress components. According to Bazants crack band theory,29,30 the
For example, the ber tension failure strain is calcu- damage energy dissipated per unit volume Gm for uni-
lated from t1 SEt11 . The damage development in the axial or shear stress condition is related to the critical
material initiates when the value of g^ m exceeds the strain energy release rate GC along with the character-
initial damage threshold of ^m 1. Further damage istic length LC of the nite element as follows
growth occurs when the value of g^ m in the current GCm
stress state exceeds the value of ^m in the previous load- Gm 9
LC
ing history.25
where m is the failure mode number.
Damage evolution laws. The evolution of the damage This condition was used to adjust the laws for the
threshold values ^m is expressed by the three Kuhn damage variables or the damage evolution laws. In this
Tucker conditions, i.e. _^ m 0, gm 0 and gm paper, an analytical procedure was performed to iden-
^ m 0,3,22 where _^ m @@T ^m
, in which T is time. tify a suitable degradation law. First, a two-coecient
Neglecting viscous eects, the DAFs of equation (6)
always have to be non-positive.24,25 While gm is negative,
the material response is elastic. When the strain state
St
"1 "1
Fiber direction 1 g^ t1 For "1 4 0 For "1 5 0
t1 c1
"2 "2
Matrix direction 2 g^ t1 For "2 4 0 For "2 5 0
t2 c2
Sc
"3 "3
Matrix direction 3 g^ t3 For "3 4 0 For "3 5 0
t3 c3
Figure 1. Proposed stressstrain relation for CDMM.
El-Sisi et al. 5
material law is proposed for the stressstrain relation propagation is aligned with the mesh lines, the charac-
i "i . To nd these coecients, the following two equa- teristic length must be the square root of the area cor-
tions were used responding to an element integration point.29,30 Unlike
Z ABAQUS,3 in ANSYS USERMAT subroutine28 there
1
GCm is no direct variable to determine the characteristic
m m Sm ; Gm m "i @"i 10
0 Lc length. To solve this problem, an ANSYS function
called get_ElmData128 was used. This function returns
where i is the direction corresponding to the mode m. the volume associated with each integration point VIP.
By solving the produced material law, m m , with the In this study, as 3D elements are used, the cubic root of
proposed damage threshold function ^m , another func- this volume VIP p was
assumed to be the characteristic
tion in terms of dm and ^m instead of i and "i can be length, i.e. Lc 3 VIP .
^ The proposed material
found, where I I : d : .
laws are listed in Table 3 along with the corresponding
damage activation laws. For the exponential damage Implementation of user subroutines
law case, Camanho and Matthews19 found the same
damage evolution law. The positive m adjustment
ANSYS User Material Subroutine
parameter can be dened as follow The user material subroutine (USERMAT) is an
ANSYS user-programmable feature.28 Its function is
2S2m Lc to allow users to write their own material constitutive
m 11 equations within a newly developed general material
2Ei Gm Lc S2m
framework. This subroutine is called at all material
where i is the direction corresponding to the mode m. integration points of these elements during the solution
Therefore, the maximum size for the nite element phase. The input parameters for the USERMAT sub-
for each damage law m is Lc 5 2ESi2Gm .23 If an FEM routine are dened in the modeling stage before the
m
contains elements with LC larger than 2ESi2Gm , the para- solution. In the eld of damage mechanics and compo-
m
site materials modeling, there is very limited research
meter m will be negative and the mesh becomes unfea-
that uses ANSYS USERMAT in the modeling.
sible. This can be avoided byq reducing
the Berbero3 developed a group of 2D models based on
corresponding strength form Sm 5 2ELi Gc m ,29 and in damage mechanics to simulate the matrix failures in
this case the damage variable will take its maximum composites; all the implementations were done using
value of 1 if ^m 4 1.23 USERMAT. Elisa16 used USERMAT in the damage
For a 2D rectangular element with an unknown model of a plate with a hole.
direction of crack propagation, the average
p
of this
expression can be used, Lc 1:12 AIP , where AIP is
the area associated with each integration point. When
Tangent stiffness operator
the crack propagation path can be estimated in To obtain a fast convergence rate of the solution algo-
advance, it is recommended to align the mesh with rithm for the nonlinear problem, it is necessary to cal-
the direction of crack propagation because cracks culate correctly the material tangent constitutive tensor
tend to evolve along the mesh lines. If the crack TM.23 The following equations were used to derive the
tangent stiness operator.3
Table 3. Material degradation law and corresponding damage C:"
evolution law. @C @d @^
_ C_ : " C : "_ "_ : " C : "_
Degradation @d @^ @" 12
law Material law Damage law @ @d @^
C : "_ TM : "_
@d @^ @"
m 1
Linear m B A"m dm 1 1
2 ^m The previous expression for TM was used in the
2
2 2m 3 CDMM model only, while for PDM and SPDM
Quadratic m BA "m dm 1 1 ^m models, TM was used as equal to C.
9^m m
1
Exponential m BeA"m dm 1 em 1^m
^m Finite element modeling
Note: A & B are material law constants, is the adjustment parameter of A 20-node layered solid element28 was used to perform
damage law. all the FE modeling. For each layer, ve integration
Table 4. Time elapsed for each analysis and solution warnings and errors.
Time (minutes)
El-Sisi et al. 7
LR=57%
LR=63%
the localization
Figure 3. Development of damage localization for CDMM at different load ratio LR values.
points through the layer thickness were used. The thick- the element type used is described in the Finite element
ness was divided to more than one element, and one or modeling section. The laminate is composed of a single
two layers were assigned to each element by using the unidirectional layer with a thickness of 1 mm. One-
layup section option in ANSYS.28 quarter mesh of the model is given in Figure 2, which
shows the dimensions, constrains, and loading direc-
tion. The ber orientation is perpendicular to the load-
Validation and discussion ing direction, so that the matrix is subjected to tension
failure. The material properties are given in Table 5 for
Solution and computational cost
the two laminates T300/1034 and T800H/3633 used in
The solution was performed under windows 64 bit plat- this study.
form, the CPU was Intel Core i7 and the random access Figure 3 shows the development of damage localiza-
memory (RAM) was 6 GB. The solution was per- tion. It can be seen that the crack began at 52% of total
formed using ANSYS version 14.5 default setting for applied load (P 30 MPa) and propagated until it
memory and CPU management.28 Table 4 represents reached the entire width of the specimen, section I.
the time elapsed to reach the failure load. As mentioned Localization is a natural phenomenon, which is often
in the Tangent stiness operator section, there are no dicult to obtain with a numerical model. An
algorithms available for the tangent stiness tensor for objective model was found to capture localization
PDM and SPDM models, which could aect the better, as it has been shown in Figure 3, which is cap-
elapsed time for both of these models. Many errors able of capturing the 3D localization. Figure 4 shows
appeared which led to too much bisection to be able the amount of damage at dierent loading levels. When
to reach the predicted failure load. the load reached 71% of the total applied load,
most of the elements that pass through section I were
completely damaged. Figure 5 shows the relation
Localization and mesh size effect
between the failure load (FL) and the number of ele-
To study the mesh size eect on each material model, a ment (NOE) for each type of damage modeling. It can
simple composite plate-with-hole model was created; be seen that increasing the NOE increases the FL for
LR=57% LR=67%
0.77 LR=71%
0.22
0.44
1.00
0.11
Figure 4. Development of damage parameter d2 for CDMM at different load ratio LR values.
1.00 1.00
Sudden Softening
0.75
0.75
Force, kN
PDM 3200
0.50
FL,kN
5000
0.50 SPDM 7200
CDDM 0.25
0.25
0.00
0.00 0.05 0.10 0.15 0.20
0.00 Displacement, mm
3200 5000 7200
Figure 6. Mesh size effect on CDMM.
NOE, #
PDM by about 26% and for SPDM by about 19%, was provided for dierent mesh densities from very
while the eect is less pronounced for CDMM by coarse to very rened,31 as shown in Figure 6. It can
about 2.5%. To evaluate objectivity, or mesh depen- be seen that the force vs displacement trends are very
dency behavior, a force (F) vs displacement relation similar in the elastic zone for all mesh sizes. After the
El-Sisi et al. 9
1.00 1.00
EXPONENTIAL
LINEAR
0.75 QUADRATIC
0.75
Force, kN
Force, kN
0.50 0.50
CDMM
SPDM 0.25
0.25
ANSYS (MPDG)
PDM
0.00
0.00 0.00 0.02 0.04 0.06 0.08 0.10
0.00 0.05 0.10 0.15 0.20
Displacement, mm
Displacement, mm
Figure 10. Forcedisplacement relation for displacement
Figure 7. Forcedisplacement relation for different models.
loaded model for the three damage activation laws.
1.00
ANSYS (MPDG) K=0.5
0.60
0.40
0.20
Figure 11. Configuration of the open-hole test specimen.
0.00
0.00 0.50 1.00 1.50 2.00 2.50
Normalized Displacement
20
1.00 Experimental[17]
EXPONENTIAL Present
16
LINEAR Maimi[23]
0.75 QUADRATIC
12
Force, kN
0.50 8
0.25 4
0
0.00 0 0.4 0.8 1.2 1.6
1.00 1.50 2.00 2.50 3.00
Displacement, mm
elastic zone, a nonlinear behavior began, followed by a the normalized displacement, relative to the failure dis-
sudden softening behavior at which large displacement placement. It can be seen that when the failure criteria
increments were achieved with very small load incre- was met, the stiness was decreased directly with the
ments up to failure. value of the degradation factor.
Figure 7 shows the force vs displacement relation for
the present three models (CDMM, SPDM, and PDM)
in addition to ANSYS (MPDM). The degradation
factor for all the failure modes was 0.995. It can be
Effect of damage evolution law
seen that the results of ANSYS MPDM and PDM Figure 9 shows the relation between dt2 and the damage
are close. Furthermore, it is observed that after the threshold function ^ for the three proposed damage
rst ply damage point at about 1.7 kN, the stiness of evolution laws, while Figure 10 shows the forcedispla-
ANSYS MPDM and PDM was aected sharply more cement relation under displacement control. It can be
than the other models. This can be attributed to the seen from Figure 10 that changing the damage evolu-
degradation factor being almost zero. Figure 8 shows tion law does not have a signicant eect on the load
a relation between the ber tension failure index and displacement relation. Displacement control loading
mechanism can capture the softening behavior of a
damaged material very well. In addition, the model
could still be solved even with partial damage and con-
30
tinue to total failure without instability errors that are
Experimental [16]
25
normally found in the case of force-control loading
PDM
SPDM
mechanism.
20 CDMM
Force, kN
15
Validation of finite element models
10 Two dierent laminates were considered in this section
from the existing literature.17,16,32 The rst laminate
5 was tested in tension, and is composed of plies made
from T300/1034-C carbon/epoxy composite (Table 5)
0 with a stacking sequence of [0/(45)3/903]s. The dimen-
0.00 0.40 0.80 1.20 1.60
sions of the test specimen were length L 203.2 mm,
Displacement, mm
thickness H 2.616 mm, and width W 25.4 mm.17,23
Figure 13. Comparison between numerical and experimental The corresponding diameter of the central hole for
results for the compression test of T800H/3633 laminate. this laminate was D 6.35 mm. The second rectangular
(a) (b)
0.88 0.44
1.00
0.77
Figure 14. Damage Parameter of T800H/3633 laminate CDMM damage model. (a) 3D damage localization and (b) damage
parameter dt2 contours.
El-Sisi et al. 11
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