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Prediction of Sub-Element and Common Feature Test Component Failure Using Continuum Damage Modeling

YURI NIKISHKOV, GENNADIY NIKISHKOV, GUILLAUME SEON, BRIAN SHONKWILER, ANDREW MAKEEV, JOSEPH SCHAEFER, BRIAN JUSTUSSON, SALVATORE LIGUORE

Abstract


Advanced structural analysis methods, known as progressive damage and failure analysis (PDFA) tools, are being developed to predict initiation and propagation of damage under repeated loading based on capturing multiple failure modes and their interaction. The Air Force Research Laboratory (AFRL) Composite Airframe Life Extension (CALE) Program, Assessing the Durability and Damage Tolerance of Advanced Composite Structural Features, has been evaluating the applicability of these methods to assess the durability and damage tolerance of composite structures within the United States Air Force fleet for service life extension. In particular, this program focused on a Common Feature Test Component (CFTC) representative of key aircraft design considerations and failure modes. CFTC advanced structural features include a composite skin made of unidirectional tape, a fabric hat stiffener, and a mechanically fastened aluminum rib. CFTC has been the most complex PDFA validation article to date. An investigation of key CFTC failure modes was performed in this work using simpler representative structural features. The subelements were modeled for finite element analysis using fiber-aligned meshing for damage modeling in bulk elements and cohesive elements for delamination modeling. CDMat – an ABAQUS plugin implementing progressive damage and failure simulation technique developed at the University of Texas Arlington Advanced Materials and Structures Lab, was used for ply-level damage progression and failure modeling under static and cyclic loads. This work presents failure and damage growth comparisons of sub-element tests and simulations by CDMat under static and fatigue loads including the comparison of fatigue delamination growth obtained for multiple maximum loads using high-resolution camera measurements. Finally, blind predictions of critical failure loads and post-critical damage growth for the CFTC specimens are compared with test results.


DOI
10.12783/asc34/31407

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