Some Practical Considerations for Compression Failure Characterization of Open-Cell Polyurethane Foams Using Digital Image Correlation.

(1) Background: Open-cell polyurethane foam mechanical behavior is highly influenced by microstructure. The determination of the failure mechanisms and the characterization of the deformation modes involved at the micro scale is relevant for accurate failure modeling. (2) Methods: We use digital image correlation (DIC) to investigate strain fields of open-cell polyurethane foams of three different densities submitted to compression testing. We analyze the effect of some DIC parameters on the failure pattern definition and the equivalent strain magnification at the apparent ultimate point. Moreover, we explore speckle versus non-speckle approaches and discuss the importance of determining the pattern quality to perform the displacement correlation. (3) Results: DIC accurately characterizes the failure patterns. A variation in the subset size has a relevant effect on the strain magnification values. Step size effect magnitude depends on the subset size. The pattern matching criterion presented little influence (3.5%) on the strain magnification. (4) Conclusion: The current work provides a comprehensive analysis of the influence of some DIC parameters on compression failure characterization of foamed structures. It highlights that changes of subset and step sizes have a significant effect on the failure pattern definition and the strain magnification values, while the pattern matching criterion and the use of speckle have a minor influence on the results. Moreover, this work stands out that the determination of the pattern quality has a major importance for texture analysis. The in-depth, detailed study carried out with samples of three different apparent densities is a useful guide for DIC users as regards texture correlation and foamed structures.

An Experimental and Numerical Investigation to Characterize an Aerospace Composite Material with Open-Hole Using Non-Destructive Techniques.

In this study, the open-hole quasi-static tensile and fatigue loading behavior of a multidirectional CFRP thick laminate, representative of laminates used in the aerospace industry, is studied. Non-destructive techniques such as infrared thermographic (IRT) and digital image correlation (DIC) are used to analyze the behavior of this material. We aim at characterizing the influence of the manufacturing defects and the stress concentrator through the temperature variation and strain distribution during fatigue and quasi-static tests. On the one hand, the fatigue specimens were tested in two main perpendicular directions of the laminate. The results revealed that manufacturing defects such as fiber waviness can have a major impact than open-hole stress concentrator on raising the material temperature and causing fracture. In addition, the number of plies with fibers oriented in the load direction can drastically reduce the temperature increment in the laminate. On the other hand, the quasi-static tensile tests showed that the strain distribution around the hole is able to predict the crack initiation and progression in the external plies. Finally, the experimental quasi-static tests were numerically simulated using the finite element method showing good agreement between the numerical and experimental results.

A New Cutting Device Design to Study the Orthogonal Cutting of CFRP Laminates at Different Cutting Speeds.

Carbon Fiber-reinforced plastics (CFRPs) are widely used in the aerospace industry due to their highly mechanical properties and low density. Most of these materials are used in high-risk structures, where the damage caused by machining must be controlled and minimized. The optimization of these processes is still a challenge in the industry. In this work, a special cutting device, which allows for orthogonal cutting tests, with a linear displacement at a wide range of constant cutting speeds, has been developed by the authors. This paper describes the developed cutting device and its application to analyze the influence of tool geometry and cutting parameters on the material damage caused by the orthogonal cutting of a thick multidirectional CFRP laminate. The results show that a more robust geometry (higher cutting edge radius and lower rake angle) and higher feed cause an increase in the thrust force of a cutting tool, causing burrs and delamination damage. By reducing the cutting speed, the components with a higher machining force were also observed to have less surface integrity control.

Analysis of the Machinability of Carbon Fiber Composite Materials in Function of Tool Wear and Cutting Parameters Using the Artificial Neural Network Approach.

Local delamination is the most undesirable damage associated with drilling carbon fiber reinforced composite materials (CFRPs). This defect reduces the structural integrity of the material, which affects the residual strength of the assembled components. A positive correlation between delamination extension and thrust force during the drilling process is reported in literature. The abrasive effect of the carbon fibers modifies the geometry of the fresh tool, which increases the thrust force and, in consequence, the induced damage in the workpiece. Using a control system based on an artificial neural network (ANN), an analysis of the influence of the tool wear in the thrust force during the drilling of CFRP laminate to reduce the damage is developed. The spindle speed, feed rate, and drill point angle are also included as input parameters of the study. The training and testing of the ANN model are carried out with experimental drilling tests using uncoated carbide helicoidal tools. The data were trained using error-back propagation-training algorithm (EBPTA). The use of the neural network rapidly provides results of the thrust force evolution in function of the tool wear and cutting parameters. The obtained results can be used by the industry as a guide to control the impact of the wear of the tool in the quality of the finished workpiece.

Numerical Modelling of Ballistic Impact Response at Low Velocity in Aramid Fabrics.

In this study, the effect of the impact angle of a projectile during low-velocity impact on Kevlar fabrics has been investigated using a simplified numerical model. The implementation of mesoscale models is complex and usually involves long computation time, in contrast to the practical industry needs to obtain accurate results rapidly. In addition, when the simulation includes more than one layer of composite ply, the computational time increases even in the case of hybrid models. With the goal of providing useful and rapid prediction tools to the industry, a simplified model has been developed in this work. The model offers an advantage in the reduced computational time compared to a full 3D model (around a 90% faster). The proposed model has been validated against equivalent experimental and numerical results reported in the literature with acceptable deviations and accuracies for design requirements. The proposed numerical model allows the study of the influence of the geometry on the impact response of the composite. Finally, after a parametric study related to the number of layers and angle of impact, using a response surface methodology, a mechanistic model and a surface diagram have been presented in order to help with the calculation of the ballistic limit.

Experimental Analysis of the Influence of Drill Point Angle and Wear on the Drilling of Woven CFRPs.

This paper focuses on the effect of the drill geometry on the drilling of woven Carbon Fiber Reinforced Polymer composite (CFRPs). Although different geometrical effects can be considered in drilling CFRPs, the present work focuses on the influence of point angle and wear because they are the important factors influencing hole quality and machining forces. Surface quality was evaluated in terms of delamination and superficial defects. Three different point angles were tested representative of the geometries commonly used in the industry. Two wear modes were considered, being representative of the wear patterns commonly observed when drilling CFRPs: flank wear and honed cutting edge. It was found that the crossed influence of the point angle and wear were significant to the thrust force. Delamination at the hole entry and exit showed opposite trends with the change of geometry. Also, cutting parameters were checked showing the feed's dominant influence on surface damage.