Applied Mechanics and Materials Vols. 13-14

Abstract: The measurement of residual stress using the incremental hole drilling is well established, but the main limitations with the conventional strain gauge approach are the requirements for surface preparation, the need for accurate alignment and drilling, the restricted range of hole geometries commensurate with the specific gauge designs, and the limited range of strain data averaged over the footprint of the strain gauge grid. Recent attempts to extend the method have seen the application of full field optical techniques such as electronic speckle pattern interferometry and holographic interferometry for measuring the strain fields around the hole, but these methods are sensitive to vibration and this limits their practical use to controlled laboratory environments. There are significant potential benefits therefore of using a more robust technique based on Digital Image Correlation (DIC), and work is presented in this study on the development of the method for measuring surface displacements and strain fields generated during incremental hole drilling. Some of the practical issues associated with the technique development, including the optimization of applied patterns, the development of the optical system and integration with current hole drilling equipment are discussed, and although measurements are only presented for a single load case - the equi-biaxial stress state introduced during shot peening - the novel aspect of this work is the integration of DIC measurements with incremental drilling and an application of the Integral Method analysis to measure the variation of residual stress with depth. Validation data comparing results from conventional strain gauge data and FE models is also presented.

Abstract: This article presents a first approach of hygrothermal microcracking in stitched crossply laminates. The presentation includes the definition of the material mesostructure and the selection of a characterization method adapted to the specificity of the study. The hygrothermal loading selected is discussed and the evolution of the crack density in stitched crossply composites during the loading is presented and commented.

Abstract: This paper discusses the penetration behavior of fully supported sandwich panels with micro-lattice and foam cores, and composite skins. This behaviour is of importance during foreign object impact and perforation of sandwich structures. Experimental results are given for quasi-static penetration of micro-lattice and foam blocks, and it is shown that these two cellular materials are comparable. Experimental results are also given for drop weight penetration of fully supported skinned panels, and it is shown that skin failure and core penetration are also similar for the two core materials. It is concluded that there is scope for improving the performance of micro-lattice structure and so making such material superior to that of aluminium foam.

Abstract: The nonlinear load-displacement and normal stress distribution in composite sandwich beams made of unidirectional carbon/epoxy facings and PVC foam cores under bending was studied. The carbon/epoxy after an initial linear response exhibits a stiffening nonlinearity in tension and a softening nonlinearity in compression with the longitudinal strength in tension higher than that in compression. The foam core also presents a nonlinear stress-strain response. It was obtained that the load-displacement behaviour of the beam, after an initial linear part, is not linear. This behavior was modeled by an incremental strength of materials nonlinear analysis. The theoretical predictions were in good agreement with the experimental results. Furthermore, it was obtained that the neutral axis of sandwich beams under bending does not pass through the centroid of the cross section, but is displaced toward the tensile side of the beam. Experimental results by moiré measurements of the in-plane horizontal displacements of the core material corroborated the analytical predictions. These findings imply higher compressive and smaller tensile stresses in the core, than those predicted for facings with identical stress-strain behaviour in tension and compression, and should be taking into consideration in the failure analysis of sandwich beams.

Abstract: The sensitivity of the thermoelastic response to variations in the fibre volume fraction, resin material and manufacturing route is assessed. To quantify any effects a comprehensive materials testing programme has been conducted to obtain coefficients of thermal expansion, specific heat, density and the elastic properties, which is described in detail in the paper. The work is focused on attempting to ascertain if the source of the response is from the isotropic resin rich layer or from the orthotropic substrate. It is also demonstrated that small variations in material properties can have a significant effect on the calculated thermoelastic response.

Abstract: This paper presents the experimental results obtained of flexurally loaded wind turbine blade cross section material. All material was extracted from a wind turbine blade box girder and testing was conducted in four point configuration. The aim was to gain an understanding of the structural integrity of this lightweight material as it deforms in flexure. To allow for thorough analysis, digital image correlation (DIC) was used to produce full field strain maps of the deforming specimens. Results highlight the capability of the DIC technique to identify regions of failure, as well as the aspects responsible for them. Overall, the results present a foundation for tests on larger substructure, and eventually integration into manufacturing and maintenance aspects of the industry.

Abstract: Locating defects and classifying them by their size was done with an Adaptive Neuro Fuzzy Procedure (ANFIS). Postulated void of three different sizes (1x1 mm, 2x2 mm and 2x1 mm) were introduced in a bar with and without a notch. The size of a defect and its localization in a bar change its natural frequencies. Accordingly, synthetic data was generated with the finite element method. A parametric analysis was carried out. Only one defect was taken into account and the first five natural frequencies were calculated. 495 cases were evaluated. All the input data was classified in three groups. Each one has 165 cases and corresponds to one of the three defects mentioned above. 395 cases were taken randomly and, with this information, the ANN was trained with the backpropagation algorithm. The accuracy of the results was tested with the 100 cases that were left. This procedure was followed in the cases of the plain bar and a bar with a notch. In the next stage of this work, the ANN output was optimized with ANFIS. The accuracy of the localization and classifications of the defects was improved.

Abstract: A method is presented to demonstrate the use of artificial neural networks (ANNs) in providing additional information regarding defects or flaws when used in conjunction with the ultrasonic A-scan method. ANNs were employed both as pattern classifiers and as function approximators to maximise the amount of data available from the temporal A-scan signal. A steel bar was modelled in 2D using ABAQUS finite element analysis (FEA) software. A single defect was introduced to the bar, modelled as a void, and parametric studies conducted to record data with the defect at various locations. An ultrasonic Lamb wave was introduced at the top of the bar. The longitudinal wave propagated along the length of the bar and was partially reflected by the defect. Multiple cases were simulated, modelling voids between 1mm and 6mm in width in various locations. Mean displacement of all the nodes at the top of the bar was recorded throughout the simulation, and features extracted from this waveform to create the data set for the ANNs. The ANNs were trained with a percentage of the data collected, selected at random, and assessed with the remaining data. The target data for the ANNs were the depth and size of the defect. The case of two separate defects was also investigated. The procedure was carried out in the same manner as for one defect, but in this case the target data for the ANNs were the depth of the first defect and the distance between the defects. A separate ANN was employed as a pattern classifier, to determine if the reflected A-scan signal represented one or two defects. The final system was tested using previously unseen data, and provided very good results both in determining the number of defects and the size and location of the defects, even with data to which noise had been added.

Abstract: Metallographic techniques are crucial tools for establishing the connection between observed mechanical behaviour of metals and the underlying mechanisms in their microstructures. In this work, we propose a methodology that minimizes deformation and/or modification of the microstructure during specimen preparation, and provides a 3D representation of the deformed micromorphology. This methodology involves opening up fractured (tensile test) specimens under the ductile-to-brittle transition temperature of metals to yield two parts in a brittle manner. The occurrence of brittle fracture is validated by analyzing the detailed, unaltered microstructure from SEM characterization and surface profilometry mapping of sets of two parts. It is found that this technique yields additional valuable information regarding the size and morphology of deformed grains or nucleation mechanisms of ductile damage. Experiments with a number of different steels show that the methodology can be applied to sheet of different formability.

Abstract: The goal of this paper is to present the results obtained from damage evaluation in automotive axles, which are under torsion fatigue. For this purpose, a Nonlinear Damage Model is used. The mentioned shafts have to satisfy geometry requirements and their material has to be heat treated in order to improve their performance. One has to keep in mind that fatigue strength depends on material properties and geometry. In order to make a precise evaluation of the accumulated damage, the manufactured shafts were tested. In the first instance, the mechanical properties of the material were evaluated with static torsion tests. In the next step, the S-N curves were obtained with torsion fatigue tests. In all these cases, temperature was controlled. Experimental data at different load levels was gathered with strain gages in conjunction with a data acquisition system. The life cycle history of each tested shaft was stored and with this experimental evidence, damage curves were obtained and the cumulative damage of the axle was established. With these damage curves, it is possible to define the relation between damage rate and life for different stress levels.