Mechanics of Pure Bending and Eccentric Buckling in High-Strain Composite Structures.

To maximize the capabilities of nano- and micro-class satellites, which are limited by their size, weight, and power, advancements in deployable mechanisms with a high deployable surface area to packaging volume ratio are necessary. Without progress in understanding the mechanics of high-strain materials and structures, the development of compact deployable mechanisms for this class of satellites would be difficult. This paper presents fabrication, experimental testing, and progressive failure modeling to study the deformation of an ultra-thin composite beam. The research study examines the deformation modes of a post-deployed boom under repetitive pure bending loads using a four-point bending setup and bending collapse failure under eccentric buckling. The material and fabrication challenges for ultra-thin, high-stiffness (UTHS) composite boom are discussed in detail. The continuum damage mechanics (CDM) model for the beam is calibrated using experimental coupon testing and was used for a finite element explicit analysis of the boom. It is shown that UTHS can sustain a bending radius of 14 mm without significant fiber and matrix damage. The finite element model accurately predicts the localized transverse fiber damage under eccentric buckling and buckling stiffness of 15.6 N/mm. The results of the bending simulation were found to closely match the experimental results, indicating that the simulation accurately shows deformation stages and predicts damage to the material. The findings of this research provide a better understanding of the structure characteristics with the progressive damage model of the UTHS boom, which can be used for designing a complex deployable payload for nano-micro-class satellites.

Effect of Resin Bleed Out on Compaction Behavior of the Fiber Tow Gap Region during Automated Fiber Placement Manufacturing.

Automated fiber placement is a state-of-the-art manufacturing method which allows for precise control over layup design. However, AFP results in irregular morphology due to fiber tow deposition induced features such as tow gaps and overlaps. Factors such as the squeeze flow and resin bleed out, combined with large non-linear deformation, lead to morphological variability. To understand these complex interacting phenomena, a coupled multiphysics finite element framework was developed to simulate the compaction behavior around fiber tow gap regions, which consists of coupled chemo-rheological and flow-compaction analysis. The compaction analysis incorporated a visco-hyperelastic constitutive model with anisotropic tensorial prepreg viscosity, which depends on the resin degree of cure and local fiber orientation and volume fraction. The proposed methodology was validated using the compaction of unidirectional tows and layup with a fiber tow gap. The proposed approach considered the effect of resin bleed out into the gap region, leading to the formation of a resin-rich pocket with a complex non-uniform morphology.

Modeling compressive behavior of open-cell polymerized high internal phase emulsions: effects of density and morphology.

The compressive behavior of poly(HIPE) foams was studied using the developed micromechanics based computational model. The model allowed identifying the morphological parameters governing the foam compressive behavior. These parameters comprise: (i) foam density, (ii) Sauter mean diameter of voids calculated from the morphological analysis of the polydispersed microstructure of poly(HIPE), and (iii) polymer/strut characteristic size identified as the height of the curvilinear triangular cross-section. The model prediction compared closely with the experiments and considered both the linear and plateau regions of the compressive poly(HIPE) behavior. The computational model allows the prediction of structure-property relationships for poly(HIPE) foams with various relative densities and open cell microstructure using the input parameters obtained from the morphology characterization of the poly(HIPE). The simulations provide a pathway for understanding how tuning the manufacturing process can enable the optimal foam morphology for targeted mechanical properties.