Composite Materials

Design, Analysis & Applications

Dr. S. Kamran Afaq

 Composite Materials

OUTLINE

• Introduction Week-1

• Mechanical Behavior
Week-2,3
• Laminated Composite Materials

• Analysis and Design Week-4,5

• Sandwich Structures
Week-6
• Manufacturing Processes
 Composite Materials

OUTLINE

Analysis and Design

• Laminate Theory (Revision)

• Laminate Analysis Algorithm

• Sizing of Laminate
• Introduction to Mathematica

• Analysis with Mathematica

• Design and Application

• Validation with ANSYS

Introduction Mechanical Behavior Laminate Theory Sandwich Structures Analysis & Design Manufacturing/Application

Composite Materials

Revision Laminate Analysis

Classical Laminate Theory
B : Coupling
 N   A B   o  Stiffness Matrix
A : Extensional    
Stiffness Matrix M   B D    

 N x   A11 A12 A16 B11 B12 B16    xo 

N    
 y   A12 A22 A26 B12 B22 B26    yo 
 N xy   A16 A26 A66 B16 B26 B66   xyo 
   
 M x   B11 B12 B16 D11 D12 D16    x 
 M y   B12 B22 B26 D12 D22 D26    y 
    
M xy   B16 B26 B66 D16 D26 D66   xy 

D :Bending
Stiffness Matrix
Introduction Mechanical Behavior Laminate Theory Sandwich Structures Analysis & Design Manufacturing/Application

Composite Materials

Revision Laminate Analysis

Classical Laminate Theory

 N   A B   o 
   
  
M B D   
Force and Moment Resultants

h/2 h/2
Nx    x dz , Mx    x zdz
h / 2 h / 2
Introduction Mechanical Behavior Laminate Theory Sandwich Structures Analysis & Design Manufacturing/Application

Composite Materials

Revision Laminate Analysis

Classical Laminate Theory

 N   A B   o 
    
M   B D    
N
A   Q k zk 1  zk 
k 1

B   Q k
N
z 2
 z k2
k 1 
k 1 2

D   Q k
N
z 3
k 1  z k3 
k 1 3
Introduction Mechanical Behavior Laminate Theory Sandwich Structures Analysis & Design Manufacturing/Application

Composite Materials

Revision Laminate Analysis

Classical Laminate Theory Strains and Stresses in
‘k’th layer

 k  S k  k
 k  Q k  k
Introduction Mechanical Behavior Laminate Theory Analysis & Design Sandwich Structures Manufacturing/Application

Composite Materials
Laminate Analysis
Start
R
Vf, Ef, Em… etc.

EL,ET…..etc

S  Q

Laminate Code, thicknesses

Q-bar for each layer

A,B and D Matrices A

Introduction Mechanical Behavior Laminate Theory Analysis & Design Sandwich Structures Manufacturing/Application

Composite Materials
Laminate Analysis
A Forces and Moments

Global Strains Matrix { ε }ox

Stresses Matrix { σxy }k in each layer

Principal Stresses Matrix { σlt }k in each layer

XT, YT…..etc

Yes Failure Criteria No

End R
is OK
Introduction Mechanical Behavior Laminate Theory Analysis & Design Sandwich Structures Manufacturing/Application

Composite Materials
Properties of Fiber/Epoxy Plies
Unidirectional Strength of Composite (Vf = 60 %)
( In MPa )

Fiber E-glass Kevlar Carbon

XT 1250 1410 1270
XC 600 280 1130
YT 35 28 42
YC 141 141 141
S 63 45 63
Introduction Mechanical Behavior Laminate Theory Analysis & Design Sandwich Structures Manufacturing/Application

Composite Materials
Properties of Fiber/Epoxy Plies
(Vf = 60 %)

( In MPa )

Fiber E-glass Kevlar Carbon

density 2080 1350 1530
EL 45000 85000 134000
ET 12000 5600 7000
vLT 0.3 0.34 0.25
GLT 4500 2100 4200
Introduction Mechanical Behavior Laminate Theory Analysis & Design Sandwich Structures Manufacturing/Application

Composite Materials
Sizing of the Laminate
 N   A B   o 
   
  
M B D   

For a symmetric laminate;

B=0

N   A  o

M   D 
Introduction Mechanical Behavior Laminate Theory Analysis & Design Sandwich Structures Manufacturing/Application

Composite Materials
Sizing of the Laminate
By definition,
n
A   Q zk 1  zk 
k 1

Q  avg  A
1
h

h = thickness of the Laminate

 Composite Materials

OUTLINE

Analysis and Design

• Laminate Theory (Revision)

• Laminate Analysis Algorithm

• Sizing of Laminate
• Analysis with Matlab
• Design and Application

• Validation with ANSYS

Introduction Mechanical Behavior Laminate Theory Analysis & Design Sandwich Structures Manufacturing/Application

Composite Materials
Sizing of the Laminate
Introduction Mechanical Behavior Laminate Theory Analysis & Design Sandwich Structures Manufacturing/Application

Composite Materials
Sizing of the Laminate
Introduction Mechanical Behavior Laminate Theory Analysis & Design Sandwich Structures Manufacturing/Application

Composite Materials

Example-1
For a given proportions of different angles in a symmetric laminate
[0/90/45]s with thickness [3,2,1]mm, Find out Moduli of the laminate.

Glass/Epoxy laminate (Vf = 60%)

33 %
17%

0°
50%
x

0%
Introduction Mechanical Behavior Laminate Theory Analysis & Design Sandwich Structures Manufacturing/Application

Composite Materials

Moduli
33 %
17%

0°
50%
x

0%

   Qavg  

Q  avg  A
1
h
Introduction Mechanical Behavior Laminate Theory Analysis & Design Sandwich Structures Manufacturing/Application

Composite Materials

Moduli 33 %
17%

0°
50%
x e
0%

n h
A   Q zk 1  zk 
k 1

n
A   Q ek
k 1

n
1
A   Q ek
h k 1 h
Introduction Mechanical Behavior Laminate Theory Analysis & Design Sandwich Structures Manufacturing/Application

Composite Materials

Moduli
33 %
17%

0°
50%
x

0%

n
1
A   Q ek
h k 1 h

1
A  Q0 p 0  Q90 p90  Q 45 p 45  Q 45 p 45
h
Introduction Mechanical Behavior Laminate Theory Analysis & Design Sandwich Structures Manufacturing/Application

Composite Materials

Moduli
33 %
17%

0°
50%
x

0%

Ex , Ey , vxy , vyx

Page: 98
Introduction Mechanical Behavior Laminate Theory Analysis & Design Sandwich Structures Manufacturing/Application

Composite Materials

Moduli
33 %
17%

0°
50%
x

0%

Gxy
Introduction Mechanical Behavior Laminate Theory Analysis & Design Sandwich Structures Manufacturing/Application

Composite Materials

Example
For a given proportions of different angles in a symmetric laminate
[0/90/45]s with thickness [3,2,1]mm, Find Maximum allowable tensile
stresses in ‘x’ and ‘y’ direction.

Glass/Epoxy laminate (Vf = 60%)

33 %
17%

0°
50%
x

0%
Introduction Mechanical Behavior Laminate Theory Analysis & Design Sandwich Structures Manufacturing/Application

Composite Materials

Assignement-7.1
For a given proportions of different angles in a symmetric laminate
[0/90/45/-45]s with thickness [3,2,1,2]mm, Find out Moduli of the
laminate. Compare it with graphical value (Calculate error?)

Glass/Epoxy laminate (Vf = 60%)

10%
15%

0°
60%
x

15%
Introduction Mechanical Behavior Laminate Theory Analysis & Design Sandwich Structures Manufacturing/Application

Composite Materials

Max. Allowable Stress 10%

15%
2 2
 L    L T   T    LT 
2
0°
  
2
          60%
x
  S 
2
 XT   T X   YT
15%

First of all we will calculate σL, σT and σLT at σx =1 MPa for

each ply.
Now calculate σL σT and σLT at σx = (σx )max for each ply
by multiplying with

  x max 
 
 1 M Pa 
Introduction Mechanical Behavior Laminate Theory Analysis & Design Sandwich Structures Manufacturing/Application

Composite Materials

Max. Allowable Stress 10%

15%
  x max     LT  
2 2 2
   L    L T   T
2

              1
  S  
2
 1Mpa  
 T
X   XT   YT 
0°
60%
x
For a lamina
15%

 x 2max . k2  1 Mpa2
 x max  1 Mpa
k
For a laminate

1 Mpa
 x max  min  
 k 
Introduction Mechanical Behavior Laminate Theory Analysis & Design Sandwich Structures Manufacturing/Application

Composite Materials
Sizing of the Laminate
Assignement-7.2
Calculate maximum stresses (σx)max, (σy)max, (τxy)max for carbon/epoxy
Vf=65% by graph and verify it through matlab.
Introduction Mechanical Behavior Laminate Theory Analysis & Design Sandwich Structures Manufacturing/Application

Composite Materials

Example-2
For a given proportions of different angles in a symmetric laminate. Find
Maximum allowable tensile stresses in ‘x’ and ‘y’ direction and maximum
allowable shear stress.

Glass/Epoxy laminate (Vf = 60%)

10%
15%

0°
60%
x

15%
Introduction Mechanical Behavior Laminate Theory Analysis & Design Sandwich Structures Manufacturing/Application

Composite Materials

Example
?%
?%
For a complex loading.
0°
?%
Nx = -800 N/mm x
Ny = -900 N/mm
?%
Nxy = -300 N/mm

Solution

First, Find out Ultimate Strength, assuming all layers are in one direction

Gives,
( σL )u and ( εLT )u
Introduction Mechanical Behavior Laminate Theory Analysis & Design Sandwich Structures Manufacturing/Application

Composite Materials

Example
?%
?%
For a complex loading.
0°
?%
Nx = -800 N/mm x
Ny = -900 N/mm
?%
Nxy = -300 N/mm

Solution
( σL )u and ( εLT )u

Nx Ny N xy
ex  , ey  , exy 
L L  LT
Introduction Mechanical Behavior Laminate Theory Analysis & Design Sandwich Structures Manufacturing/Application

Composite Materials

Example ?%
?%
For a complex loading.
0°
?%
Nx = -800 N/mm x

Ny = -900 N/mm ?%
Nxy = -300 N/mm

Solution
Nx Ny N xy
ex  , ey  , exy 
L L  LT

ex ey exy
0  , 90  ,  45 
ex  e y  exy ex  e y  exy ex  e y  exy
Thank You