Analysis of Failure in Fiber Polymer Laminates

Martin Knops

Analysis of Failure in Fiber Polymer Laminates

The Theory of Alfred Puck
Corrected Second Printing

123

Dr.-Ing. Martin Knops REpower Systems AG Rotorblattentwicklung Hollesenstrae 15 24768 Rendsburg Germany m.knops@repower.de

ISBN 978-3-540-75764-1 DOI 10.1007/978-3-540-75765-8

Library of Congress Control Number: 2008921124

e-ISBN 978-3-540-75765-8

2008 Springer-Verlag Berlin Heidelberg New York This work is subject to copyright. All rights are reserved, whether the whole or part of the material is concerned, specifically the rights of translation, reprinting, reuse of illustrations, recitation, broadcasting, reproduction on microfilm or in any other way, and storage in data banks. Duplication of this publication or parts there of is permitted only under the provisions of the German Copyright Law of September 9, 1965, in its current version, and permissions for use must always be obtained from Springer. Violations are liable for prosecution under the German Copyright Law. The use of general descriptive names, registered names, trademarks, etc. in this publication does not imply, even in the absence of a specific statement, that such names are exempt from the relevant protective laws and regulations and therefore free for general use. Typesetting and production: le-tex publishing services oHG, Leipzig, Germany Coverdesign: WMXDesign GmbH, Heidelberg Printed on acid-free paper 98765432 springer.com

Foreword

In 1948 when I began to study mechanical engineering in the ruins of the School of Engineering in Hamburg common opinion was that designing of components was not a science but an art. Since then things have changed significantly. There is no doubt that a designer of composite components needs a lot of practice and a certain artistic skill but he also needs a good understanding of fundamental theory. Unfortunately still some people feel that theory is far away from practice. Personally I refer to great researchers such as the famous chemist A.L. Lavoisier (17431794) and the well known German scientist and teacher in aerodynamics L. Prandtl (1875 1953); it was him who said There is nothing more practical than a good theory! Possibly this can be a modification of the much older statement of Lavoisier: There is nothing more practical than a good hypothesis! An FRP-laminate is a very sophisticated multilayered structure with skillfully tailored anisotropy. Analyzing the fracture processes in FRPlaminates needs a theory which is able to describe the different fracture mechanisms fundamentally correctly. I use as a good hypothesis the one created by Otto Mohr (18351918): The fracture limit of a material is determined by the stresses on the fracture plane. From time to time some authors have proposed to apply this hypothesis to brittle composites. This was most forcibly argued by Hashin [Hashin 1980]. But time had not yet come for that approach. That is to say a certain computing capacity has to be available to identify the orientation of the fracture plane, which is unknown a priori. First one had experimentally to investigate whether or not a modified Mohr-Hypothesis would be acceptable for UD-composites. Parallel to my theoretical approaches I found invaluable help for the experimental task from Ph-D candidates of the Aachen Technical University. Very often I told these young colleagues about my feelings that there is an excessive production of theories but a considerable lack of reliable experimental results. Unfortunately nowadays experimental work is not appreciated as much as it should be. Nevertheless the young colleagues from Aachen have chosen the experimental problems proposed by me as the subject of their dissertation. This way they supplied the experimental verification of my theory. I am extremely grateful for this assistance and therefore I want

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to list the names of all the experimenters: Dirk Huybrechts (1996), Jochen Kopp (2000), Martin Knops (2003), author of this book, Oliver Fischer (2003), Martin Mannigel (2007) and Erik Kuhnel (2008)1. My theory has now arrived in practice. Also the incorporation of my theory into the Guideline VDI 2014 (Verein Deutscher Ingenieure) as well as into guidelines of Germanischer Lloyd and Det Norske Veritas shows the same acceptance. For the readers of this book, VDI 2014 Part 3 Development of Fiber Reinforced Plastic Components, Analysis can be a very helpful supplement. It is written throughout in German and English. The reason that my theory has been treated in VDI 2014 so profoundly and prepared for use in practice is mainly the credit of my cooperation with Mr. Gnther Lutz, who is a very experienced designer and developer of FRP-Couplings and large FRP-Drive shafts for fast ships. In the future the Composite Technology will play an important role for the development of energy saving vehicles and technologies for environment and climate protection. The author of this book is working in this field already, developing large rotor blades for wind turbines. The fact that design engineers, using composites, have an enormous freedom in the design of custom made materials for special needs is a fascinating experience. Nevertheless this fascination should not stop us from thinking about the ultimate usage of our products. As can be expected one can find many composites in modern weapon systems including intercontinental ballistic missiles. It should not be our goal to develop even more weapons or make them more effective. The problem will ever be: How can we get rid of them before everyone will have them? I hope that the book of Martin Knops will satisfy many interested and critical readers. I am confident that the readers will have some delightful ahaa experiences. For myself I hope that for quite a while I will still be privileged to stay in contact with young composite engineers. We should never stop learning! What I already know for a long time, is: Modern composites are black and not easy to be looked through but they are not at all products of black magic! We can understand them, if we carefully try to think about their internal construction. However thinking alone is not enough, of equal importance are smart experiments. Immenhausen, January 2008 Alfred Puck

The year in brackets is the year of the publication of the dissertation (see also References in the book)

Preface

In 2003 I was encouraged by Alfred Puck himself to write this book about his failure model and the Puck fracture criteria. The motivation was that Pucks own book from 1996 was written in German and did not cover the major progress especially in the field of validation which was achieved since. There was no comprehensive presentation of Pucks work in English language and several people asked for an English book with such content. I had at the time just finalized my dissertation about the gradual failure process for which I had worked closely together with Alfred Puck as a senior adviser. He considered me as one of the best experts and the right person to write such a book. That was of course a high honor to me and I agreed to start the project being supported and encouraged by the management of my employer, the Institute for Plastic Processing (IKV), namely Walter Michaeli and Ernst Schmachtenberg. Originally it was planned to publish in 2004, but as often in such projects this was a too optimistic assumption and after I changed from university to industry in early 2005 and started a family at the same time it became hard to find enough time for the project. I am grateful to Petra Jantzen from Springer who always polite but with the right pressure set deadlines and pushed me to work. After all, the elongation of the project offered the opportunity to implement the latest work in the field which was conducted in the recent years. Thus, value was added to the overall project. On the other hand, there are still wishes which have not been met. For sure a broader presentation of the applications of Pucks failure model would have been desirable. But now it is time for publication and this part is left out for the moment. There is a list of people who have made this book possible. First to name is of course Alfred Puck, who teached and advised me for years and who also revised this book. Gnther Lutz one of the co-authors of the VDI2014 guideline on the development of FRP components has been the main reviser of the text. I thank not only for this but also for the great profit I got from the work on the VDI2014. Additional thanks go to Walter Michaeli and Ernst Schmachtenberg who encouraged me to write this book during my time at the IKV. Besides I am very grateful to Dieter Merkle and Petra Jantzen from Springer for

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making this book possible. Last but not least I thank my wife Claudia for her understanding and patience during all the hours I worked for this book. I dedicate this book to my children Paula Liane and Peter Elias. Rendsburg, January 2008 Martin Knops

Contents

1 2

Introduction ................................................................................ Failure of laminates.................................................................... 2.1 Laminate structure ............................................................... 2.2 Micro-cracks........................................................................ 2.3 Inter Fiber Fracture (IFF) .................................................... 2.3.1 Different forms of Inter Fiber Fracture (IFF) ........... 2.3.2 Relevance of IFF....................................................... 2.4 Delamination ....................................................................... 2.5 Fiber Fracture (FF) .............................................................. 2.6 Laminate Failure.................................................................. 2.7 Summary of chapter............................................................. Stress and strength analysis: Basics and definitions ............... 3.1 Coordinate systems, stresses and stressings ........................ 3.1.1 Natural coordinate system of the UD-lamina ........... 3.1.2 Coordinate system of the laminate............................ 3.1.3 Stresses of the UD-lamina ........................................ 3.1.4 Stressings of a UD-element ...................................... 3.1.5 Stresses on the fracture plane, adapted coordinate system......................................... 3.1.6 Coordinate system for the visualization of fracture bodies ...................................................... 3.2 Stress analysis...................................................................... 3.3 Strength analysis.................................................................. 3.3.1 Introduction............................................................... 3.3.2 Fracture condition, fracture criterion and the term stress exposure....................................................... 3.3.3 Distinguishing residual and load determined stresses ................................................... 3.3.4 Margin of safety and reserve factor of the Composite materials structure..................................................... 3.4 Summary of chapter............................................................. Pucks action plane fracture criteria ........................................ 4.1 Fiber fracture criteria ........................................................... 4.2 Inter fiber fracture (IFF) criteria ..........................................

1 5 5 6 7 10 13 14 16 18 19 21 21 21 22 22 23 24 25 27 28 28 28 32 33 34 37 37 40

Contents

Motivation................................................................. Different IFF-fracture modes.................................... Fracture hypotheses .................................................. Fracture resistance of the action plane...................... Visualization of the stress/strength problem............. Universal 3-D-formulation of the action plane related IFF-criteria .................................................... 4.2.7 Analytical 2-D-formulation for plane states of stress ..................................................................... 4.3 Extensions to the IFF-criteria .............................................. 4.3.1 Inclusion of stresses not acting on the fracture plane in the action-plane-related inter-fiber fracture criteria.......................................................... 4.3.2 Calculation of the stretch factor f SL of the loaddetermined stresses when residual stresses are present ................................................................. 4.4 Visualization of fracture bodies........................................... 4.5 Summary of chapter............................................................. 5 Analysis of the gradual failure process..................................... 5.1 Approaches for the modeling of the gradual failure process...................................................................... 5.2 Pucks approach for the analysis of the gradual failure process...................................................................... 5.2.1 Degradation procedure for cracks due to IFFMode A ... 5.2.2 Degradation procedure for cracks due to IFFMode B and IFFMode C ............................................................. 5.2.3 Pucks method from 1969......................................... 5.2.4 Degradation method used in the World Wide Failure Exercise ................................ 5.2.5 New degradation method (2007) .............................. 5.2.6 Laminates with unsound loading conditions............. 5.3 Implementation of the Puck theory for the gradual failure process in a software code ................................................... 5.4 Summary of chapter............................................................. Experimental work..................................................................... 6.1 Verification of the fracture hypotheses and calibration of the fracture body.............................................................. 6.1.1 Experiments with Three Dimensional Stress States . 6.1.2 Experiments with plane (2, 21)-stress combinations ..................................... 6.2 Experimental determination of degradation curves ............. 6.2.1 Degradation of Et and G|| for fracture Mode A ...... 6.2.2 Degradation of E and G|| for fracture Mode B.......

4.2.1 4.2.2 4.2.3 4.2.4 4.2.5 4.2.6

40 43 44 46 51 65 79 83 83 97 108 114 117 119 121 122 123 125 128 128 129 130 133 137 137 137 143 150 151 156

Contents

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6.2.3 Degradation of || and || ........................................ 6.2.4 Validation of degradation curves .............................. 6.3 Summary of chapter............................................................. 7 8 9 Implementation in software....................................................... Application of Pucks work in industrial practice .................... Concluding remarks...................................................................

157 159 167 171 175 177 179 197 203

Annex .................................................................................................. References .......................................................................................... Index ...................................................................................................