Dade Huang and Levon Minnetyan

Clarkson University, Potsdam, New York

Computational Simulation of Damage

Propagation in Three-Dimensional

Woven Composites

NASA/CR—2005-213963

October 2005
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Dade Huang and Levon Minnetyan

Clarkson University, Potsdam, New York

Computational Simulation of Damage

Propagation in Three-Dimensional

Woven Composites

NASA/CR—2005-213963

October 2005

National Aeronautics and

Space Administration

Glenn Research Center

Prepared under Grant NAG3–1101
Available from

NASA Center for Aerospace Information

7121 Standard Drive

Hanover, MD 21076

National Technical Information Service

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This report is a formal draft or working

paper, intended to solicit comments and

ideas from a technical peer group.

This report contains preliminary

findings, subject to revision as

analysis proceeds.

Available electronically at http://gltrs.grc.nasa.gov

This work was sponsored by the Low Emissions Alternative

Power Project of the Vehicle Systems Program at the

NASA Glenn Research Center.
CONTENTS 

ABSTRACT.................................................................................................................................................... 1 

1 CHAPTER 1 INTRODUCTION ..................................................................................................... 2

 1.1 Three Dimensional Composites.......................................................................................... 2 

 1.2 Stiffness Properties of Three Dimensional Composites.................................................... 5 

 1.3 Stress and Strain Analysis of Three Dimensional Composites ........................................ 11 

2 CHAPTER 2 ANALYTICAL CHARACTERIZATION OF 

 THREE DIMENSIONAL COMPOSITES...................................................................................... 16 

 2.1 Woven Patterns.................................................................................................................... 17 

 2.2 Fiber Arrangement............................................................................................................... 17 

 2.3 Three Dimensional Hygrothermoelastic Properties.......................................................... 21 

 2.4 Two Dimensional Hygrothermoelastic Properties ............................................................ 25 

 2.5 Stress in Primary Domain and Weaver Domain................................................................ 30 

 2.6 The Influence of Fiber Waviness on Stiffness................................................................... 33 

3 CHAPTER 3 PREDICTION OF 3-D WOVEN AND BRAIDED 

 COMPOSITE PROPERTIES........................................................................................................... 39 

 3.1 Methodology........................................................................................................................ 39 

 3.2 Results and Discussion........................................................................................................ 42 

4 CHPATER 4 DAMAGE PROPAGATION OF 3-D WOVEN COMPOSITES........................... 46 

 4.1 Structural Analysis Module ................................................................................................ 48 

 4.2 Failure Criteria..................................................................................................................... 49 

 4.3 Simulation of Damage Progression.................................................................................... 51 

 4.4 Damage Energy Release Rate............................................................................................. 53 

5 CHAPTER 5 DAMAGE PROGRESSION IN CARBON-FIBER 

 PLASTIC I-BEAMS......................................................................................................................... 56 

 5.1 Introduction.......................................................................................................................... 56 

 5.2 Methodology........................................................................................................................ 59 

 5.3 Carbon-Fiber Reinforced Plastic I-Beams ......................................................................... 64 

 5.4 Fiber and Matrix Properties Calibration ............................................................................ 66 

 5.5 Results and Discussion........................................................................................................ 70 

 5.6 Conclusion ........................................................................................................................... 77 

6 CHAPTER 6 COMPUTATIONAL SIMULATION OF PROGRESSIVE FRACTURE IN 

STITCHED J-STIFFENED COMPOSITE SHEAR 

 PANELS IN THE POSTBUCKIING RANGE............................................................................... 81 

 6.1 Introduction.......................................................................................................................... 81 

 6.2 Methodology........................................................................................................................ 83 

 6.2.1 Evaluation of Elastic Constants................................................................................. 83 

 6.2.2 Finite Element Analysis............................................................................................. 84 

 6.2.3 Failure Criteria ........................................................................................................... 85 

 6.2.4 Simulation of Damage Progression........................................................................... 86 

 6.2.5 Damage Energy Release Rate ................................................................................... 87 

 6.3 J-Stiffened Composite Panels ............................................................................................. 88 

 6.4 Fiber and Matrix Properties Calibration ............................................................................ 88 

 6.5 Results and Discussion........................................................................................................ 92 

 6.5.1 Analysis without Considering Lateral Buckling of the Skin................................... 93 

 6.5.2 Postbuckling Analysis................................................................................................ 94 

 6.5.3 Analysis of Panels with other lay-ups....................................................................... 96 

 6.6 Conclusion ........................................................................................................................... 96 

7 CHAPTER 7 COMPUTATIONAL SIMULATION OF PROGRESSIVE 

 FRACTURE IN CERAMIC MATRIX COMPOSITES ................................................................ 101 

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 7.1 Introduction.......................................................................................................................... 101 

 7.2 Micro and Macro-mechanical Characterization of Ceramic Matrix Composites............ 102 

 7.3 Failure Criteria for Ceramic Matrix Composites............................................................... 107 

 7.4 Progressive Fracture Simulation......................................................................................... 109 

 7.5 Examples and Discussion.................................................................................................... 112 

 7.6 Conclusion ........................................................................................................................... 127 

8 CHAPTER 8 CONCLUSION.......................................................................................................... 

APPENDIX A Constituent Material Properties............................................................................................ 131 

APPENDIX B Comparison of Composite Properties Computed by the 3D 

 Composite Mechanics with Cox and Experimental Data .............................................................. 133 

9 CHAPTER 9 REFERENCES........................................................................................................... 145 

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Available electronically at http://gltrs.grc.nasa.gov

October 2005

NASA CR—2005–213963

E–15279

WBS–22–066–30–02

NAG3–1101

153

Computational Simulation of Damage Propagation in Three-Dimensional

Woven Composites

Dade Huang and Levon Minnetyan

Progressive fracture; Structural fracture; Three-dimensional woven composites

Unclassified -Unlimited

Subject Category: 24

Clarkson University

8 Clarkson Avenue

Potsdam, New York 13699

Project Manager, Christos C. Chamis, Research and Technology Directorate, NASA Glenn Research Center,

organization code R, 216–433–3252.

Three-dimensional (3D) woven composites have demonstrated multi-directional properties and improved transverse

strength, impact resistance, and shear characteristics. The objective of this research is to develop a new model for

predicting the elastic constants, hygrothermal effects, thermomechanical response, and stress limits of 3D woven

composites; and to develop a computational tool to facilitate the evaluation of 3D woven composite structures with

regard to damage tolerance and durability. Fiber orientations of weave and braid patterns are defined with reference to

composite structural coordinates. Orthotropic ply properties and stress limits computed via micromechanics are

transformed to composite structural coordinates and integrated to obtain the 3D properties. The various stages of

degradation, from damage initiation to collapse of structures, in the 3D woven structures are simulated for the first time.

Three dimensional woven composite specimens with various woven patterns under different loading conditions, such as

tension, compression, bending, and shear are simulated in the validation process of this research. Damage initiation,

growth, accumulation, and propagation to fracture are included in these simulations.