Fluid Structure Interactions Research Group

Effect of geometric imperfections on the compressive response of composite panels

Mathieu Colin de Verdiere mcdv1u07@soton.ac.uk - School of Engineering Sciences CEC Marstruct funding Supervisors Dr Steve Boyd and Professor Ajit Shenoi
Motivation & Aim Ultimate objective: to asses the effect of geometrical imperfections on the compressive strength of carbon and glass composite panels (CFRP and GFRP). Currently compressed structures such as wind turbine blades are produced by resin infusion. As the blade have important aspect ratio the moulds can be rather long (Figure 3) and the blade can then be sensitive to buckling as compressive Figure 1: Bending of the wind turbine blade Source [1] properties of composites are known to be significantly lower than in tension (15 to 40 %). To make it worse it is possible to get some bashes on the mould surface after the production of several blades due to human error (a tool falling on the mould surface) or the mould deformation under heat for example. Such defects on the mould will Figure 2: typical wind turbine be transferred to the blade geometry that would cross section [1] lead to the reduction of the buckling resistance of the structure. This research considers the simulation of composite panels (GFRP and CRFP) with various lay-up and geometrical imperfections (size and depth) to simulate and investigate the reduction in buckling load and ultimate compressive strength. Secondly a novel compressive apparatus is being manufactured to allow for the buckling of the panels and the 3 D monitoring of the deformation via digital image correlation (DIC). Testing Panels made via resin infusion.

Panel testing:
o The apparatus should allow for regular enlightenment of the panel to permit DIC algorithm to perform. o The apparatus should allow for compressive loading of the panel and be representative of the in service loading as such as the one of the blade spar and skin. o The panels are compressed by an Instron test machine. o The apparatus uses anti buckling guides on its side and full clamping at its bottom. o Defects: bumps in the form of a sinus wave are used (Figure 4).

Monitoring of imperfections

Figure 4: geometrical defect

o DIC allows for the capture of the defect changes in 3D through out loading.

Specimens testing

Concept

Figure 5: Tensile, compressive and shear specimens

c) b)

Compressive apparatus
a)

Figure 3: 60 foot wind turbine mould [2]

Figure 6: a) complete apparatus, b) GFRP specimen, c) GFRP panel infused

Results Generic Panels Research has designed generic panels to be representative of wind turbine blade. [0-90] lay-up 210 x 210 mm, 4 mm thick. Bump depth vary from 0 mm to 10 mm. Bump diameter vary from 50 to 100mm.
Figure 6: axial stresses prior to buckling on small to large defects (left to right)

Simulations Parametric simulations are ran under Ansys with basic failure criteria and buckling analysis on glass and carbon fibres. A few simulations are run under PAM-CRASH with a damage models. The model is calibrated in the first instance and then ran on panels with and without defects. Conclusion Results are sensible to the compressive stiffness, strain and strength used which are difficult to acquire experimentally in the axial direction in the first instance. An Ansys input file was generated that created various numerical plates with defects rapidly. To predict better the compressive response and the defect influence; a damage model was used on CFRP and GFRP with the PAM-CRASH code. Implementing such model in Ansys was rather problematical and was avoided. Defect influence was considerable on [0/90] lay up and small on [+-45] lay up. It was also stronger on carbon than glass lay-up. Small mould defect could reduce strength by 10 to 25% on axial lay up and deeper one up to 40% . It is an issue on long structure subjected to buckling such has boat mast, wind turbine blades or glider wings. Significant safety factor should be used.

Figure 7: Ansys input model Failure criteria such as Tsai-Hill and Tsai-Wu can be applied in Fortran user subroutine Usermatps.F and compiled in Ansys. Such failure criteria could not reproduce material non linearties and failure load predictions well.

An existing damage model in an explicit code was preferred for enhanced load buckling and damage predictions and ran in PAM-CRASH.
A small amount of defect depth (0.7mm) reduces considerably strength and stiffness on unidirectional or [0/90] lay ups (more than 20%), but has little influence on bias direction lay up (less than 8%). The defect influence is greater on stiff and brittle composites (carbon) than on more compliant ones (glass). Future work: Simulation with various thicknesses Strain field monitoring Comparison of damage for different defects Comparison of numerical and experimental results References: [1] : Full scale testing of wind turbine blade to failure - flapwise loading Erik R. Jrgensen, Kaj. K. Borum, Malcolm McGugan, Christian L. Thomsen, Find M. Jensen, Christian P. Debel og Bent F. Srensen Ris National Laboratory, Roskilde June 2004 [2]: http://www.bayviewedisonindustries.com

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