Engineering Fracture Mechanics Vol. 32, No. 5, pp. 757-166, 1989 Printed in Great Britain.

$3.00 + 0.00 0013-7944/89 0 1989Pergamon Presspk.

THE REDUCTION OF STRESS CONCENTRATION AROUND THE HOLE IN AN ISOTROPIC PLATE USING COMPOSITE MATERIALS
G. S. GIARE and R. SHABAHANG Aeronautical Engineering Department, Embry-Riddle Aeronautical University, Prescott, AZ 86301, U.S.A.

Abstract-The stress distribution around a hole in a finite isotropic plate reinforced by composite material has been calculated using a finite element analysis. The results agreed very closely with experimental investigations. With the present reinforcement technique, the stress concentration factor of 2.72 for a finite plate near a hole reduces to the factor of one. The theoretical and experimental results have shown that the present reinforced around hoop-wound carbon fiber disc provides an efficient reinforcement around circular holes. This technique could be very useful in reducing the stress concentration factor of orthotopic plates of composite materials. The technique may be found to be particularly useful in composite laminate plates in which they could be incorporated during manufacturing process.

NOMENCLATURE Radius of hole Outer radius of reinforcing disc Radius greater than hole Cross-sectional area E Youngs modulus EC Modulus of graphite/epoxy EAI Modulus of aluminum G Shear modulus K Stress concentration factor P Direct load PC Load in composite Uniform applied tensile stress s Thickness of aluminum plate 1 12 Thickness of reinforcement ring Thickness of filament winding of graphite/epoxy f3 and transverse plate coordinate directions x9 Y Longitudinal c Direct strain 8 Angular coordinates Poissons ratio 0 Direct stress r Shear stress 1 Aluminum alloy plate 2 Composite material Pressure lb/in2 P Load transfer efficiency factor fl

rl

1. INTRODUCTION THE REDUCTION of stress concentration around cut-outs in a flat plate has been studied for a long time. An early paper by Gurney[ l] dealt with circular holes in plane stress, and analytical solutions were given for holes reinforced with thin uniform annuli of rectangular cross sections subjected to uniform stress in plane direct and shear loads. Later on, Reissner and Morduchow[2] considered the same problem, but with the reinforcement in the form of a bead which was treated as a curved beam. The idea of designing a bead such that the stresses in the plate remained unchanged by the cut-out was introduced {neutral holes), and a theoretical analysis by MansfieldpI gave the shape a neutral hole and the variation of the cross-sectional area of the reinforcement for any particular loading system. Since this early work, many papers have been published on the subject, and design information is now available in ref.[4], which deals with the reinforcement of circular, elliptical and rectangular holes in isotropic plates.
757

1%

G. S. GIARE

and R. SHABAHANG

D. 0. McKenzie and J. P. H. Webber studied analytically and experimentally hole reinforcement in isotropic and orthotopic plates using filament-wound discs[5]. The present work is a step further, based on what was done in[5]. In the present studies, the isotropic plate is reinforced using special winding techniques with the use of graphite fiber/epoxy systems. The unidirectional fiber layer maintains continuity of stress around the hole of the isotropic plate. In this paper, finite element analysis in the linear elastic region has been made, using the Coade program. The results are verified with experimental investigations. The stress concentration factor for a finite isotropic plate in tension is 2.72. When the plate is reinforced with graphite fiber, according to the technique presented in this paper, the stress concentration factor is only 1.25. 2. THEORY The aluminum plate with a hole, reinforced by a CFRP disc and further strengthened by graphite fiber winding, is shown in Fig. l(a). The construction of the specimen is described in Section 5.
3.6

1:
-

S = 1684 PSI IO.

ol
disc and further reinforcement

~.

1. s::I684
-!

PSI

Fig.

1(a). Reinforcement

of Alum. plate with a CFRP

with graphite/epoxy.

Fig.

1 (b). Reinforcement

of a circular

hole by a hoop-wound

CFRP

disc on each side of the plate.

Stress concentration

around a hole

759

1020

lb =

-\

IO20 lb

RADIAL PRESSURE P= 483 PSI B

1020Ib

= A

-\zl020fb

L Fig. 2. Tensile fibers inducing compressive force.

When the specimen is loaded in tension, the graphite winding AA and aluminum alloy plate behave as a composite structure. The longitudinal graphite fiber is in tension, as the graphite fiber passed through disc 2, fibers induces compressive force on the ring, as shown in Fig. 2. This compressive force causes the reduction of stress concentration factors around the hole. For the initial load of 200 lb, the load carried by the graphite fiber/epoxy composite and aluminum alloy plate may be calculated as follows: L = Q = CA, p = P, + PA,
a/E = q/E, = o$EA P = cTc.A, + a,,*A*, P =200lb PC= l/4,90 P = 40.8 lb

EA, = 10 x 1061b/in2 E, = 10 x lo6 lb/in2

P JP, = 4.9

v, = 0.25 vAL= 0.30. A, = 0.0341 in* AAl = 0.1271 in*. The load carried by P, produces compressive forces around the ring of the hole, as shown in Fig. 2. This reduces the stress concentration. The magnitude of tensile force in composite winding is equivalent to l/4.9 of the applied load. This ratio of loading can be controlled by varying the modulus of elasticity of fiber winding. 3. FINITE ELEMENT The finite element analysis was done using Coade software on an IBM AT computer. In finite element analysis, an aluminum alloy plate 1 x 20 x 40 with a hole of 2 diameter was analysed. The a/w ratio was 0.1. The same ratio was maintained in experimental investigation. EFM 32,1--P

760

G. S. GIARE and R. SHABAHANG

In the Coade program, the stress concentration around the hole in the isotropic material was modified as follows: MSH 2D was changed to accommodate two materials, one marked 2 consisting of a graphite disc around the hole and the rest of the isotrophic material marked I. Figure 3(a) shows the finite MSH 2D of the aluminum alloy plate with CFRP disc, and 3(b) shows the magnified view of mesh near hole of the plate. Theoretically, the I/4.9 P load transfer by filament graphite fiber/epoxy composite was modeled in finite element analysis as load acting inward to hoie, as shown in Fig. 4. The hoop load carried by the graphite fiber produces a radial pressure P on the diameter of disc 2, as follows:
P,!2t. I = 0, P = 483 lb/in

o;2r = P/4.712 = 1020 lb d = diameter of disc = 3.X p = radial pressure in lb,/& q = load transfer efficiency factor = 0.90 (ASSUMPTION).

s=500

PSI

I = ALUMINUM

PLATE MATERIAL

10.0

_I

2 = COMPOSITE (b)

(a)
Fig. 3. (a) Finite MSH Z&-of

Alum. plate with CFRP disc. (b) magnified view near the hole showing two different materials.

Stress concentration

around a hole

761

Fig. 4. Finite MSH 2LAlum.

plate with CFRP disc loaded at different node.

It produces a radial pressure of p = -483 lb/in* acting radially towards the center. Pressure at each node is resolved in a vertical component opposing the applied load using eq. (1) and applied -459 lb/in at node 25-26, - 392 lb/in2 at node 26-27, -295 lb/in2 at node 27-28, - 187 lb/in2 at node 28-29, - 90 lb/in2 at node 29-30. Figure 5 shows the radial pressure resolved in x-x direction,

P,= P cos26.

(1)

pg=

1020 lb

GRAPHITE

WINDING

GRAPHITE

RING

-ALUMINUM

PLATE

= -

1020 lb

25-26 26-27 27-26 26-29 29-30

459 392 295 I67 90

PSI

GRAPHITE

WINDING

Fig. 5. Radial load resolved in x-x-direction.

762

G. S. GIARE

and R. SHABAHANG

4. ELASTIC When an infinite as follows:

SOLUTION

OF INFINITE

PLATE

WITH

HOLE stress, cfl, is given

width plate is loaded in tension

with the hole the maximum

fsH= S/2[1 + al/r*] - S/2( 1 + 3a4/r4) cos 28. At the hole when r = a, r_~@ = 3, hence K = 3. For finite width K = 2.72 has been obtained using Coade finite element analysis. in this study,

(.2) 2ajw = 0.1.

5. EXPERIMENTS Uniaxial tension tests were carried out on aluminum alloy plates, with holes reinforced by filament-wound carbon fibers discs are shown in Fig. l(b). The present aluminum alloy plate with a hole reinforced by CFRP disc and further strengthened by graphite fiber winding is shown in Fig. l(a). The aluminum plate is l/32 x 3.8 x 10 is cut from aluminum alloy sheet. A hole of 0.38 in diameter is bored on a drilling machine. The hoop-wound CFRP reinforcing discs were cut from thick walled tube manufactured in the lab. on a lathe at 8 = fgg using 6K medium modulus roving graphite fiber/epoxy system. Two CFRP discs l/32 thick and 0.69 in diameter are bonded to the aluminum plate on either side surrounding the hole. Two tabs of glass-fiber laminate l/S x l/2 x l/2 are bonded symmetrically along the central line at station A and A of the aluminum plate (as can be seen in Fig. l(a). The above said tabs of the same material and dimensions are bonded on the other side of the plate. After the glass fiber tabs are cured, a slot l/32 thick and l/16 deep parallel to the aluminum plate and touching it is cut into each tab. This groove keeps the graphite fiber/epoxy winding in position. Two l/4 thick, l$, diameter perspex washers are clamped with l/4 diameter bolts and nuts on either side of the CFRP disc. These washers give a space of l/32 between aluminum plate and washer, to keep the graphite fiber impregnated in the proper position. The graphite fiber is impregnated with epoxy and wound around the slot of glass fiber epoxy laminate at station A and disc 2. The other layer is then wound around A and disc 2. This alternate winding process is continued until six layers of 6K tow fibers are completed. The same process is carried out on the other side of the aluminum plate. Care is taken that the plate remains straight, while the winding is done. The winding is pressed against the aluminum plate and allowed to cure. After curing, the perspex washers are removed. With hand lay out, the graphite composite of 33% I/; is obtained. alloy In total 12 aluminum alloy plates, l/32 x 3.8 x lo, were cut. A set of 4 aluminum plates were tested with 0.380 diameter holes. A set of 4 aluminum alloy plates reinforced with CFRP disc were made. A set of 4 aluminum alloy plates were bonded with CFRP discs and further reinforced with graphite fiber/epoxy as shown in Fig. l(a) were made also. Figure 6 shows the photographs of all the three specimens. All holes were made 0.380 in diameter. In these specimens, the reinforcing discs were placed symmetrically on each side of the hole. Each specimen was instrumented with 120 ohms electrical resistance strain gauges. Strain gauges were fixed at x = s/g, 314 and 1. Strain gauges were used, made by Measurements Group, with gauge length of 4 mm. Single gauges were bonded to the surfaces of the plates and reinforcing discs to obtain the distribution of strain in the vicinity of the hole. The hole was small; the strain gauge could not be fitted on the inner surface. Using eq. (2), the stress concentration factor was calculated at the inner edge of the hole. All the specimens up to 500 lb tension load only were tested on the tensile testing machine with a 2000 lb load cell, using strain indicator, P - 3500, manufactured by Instruments Division, Measurements Group, Raleigh, North Carolina. From the strains obtained by the gauges, the stresses are calculated, and hence stress concentration factors were obtained.

6. RESULTS

AND

DISCUSSION program, for with disc with factor vs r/a

Stress concentration factors were calculated, using Coade finite element aluminum plate, for aluminum plate with disc, and for aluminum plate reinforced further reinforcement with graphite fibers. Figure 7 shows the stress concentration

Stress concentration

around a hole

763

Fig. 6. Photograph of the three specimens.

Stress concentration

around a hole

765

4l
A

ALUMINUM PLATE ALUMINUM DISC

\ A

0 ALUMlNUM DISC WINDING

o/..........
0 I 2 3 4 5 R/A

IO

II

Fig, 7. Stress across minimum section alum. plate, CFRP-reinforced b/a = 1.8125, 1,/t, = 3.0 specimen.

alum. and

Present specimen

for all the three specimens. For aluminum plate, the stress con~ntrat~on is 2.72 at the edge of hole and reduces to one at r/a equal to 10. When the aluminum plate reinforced with orthotropic disc of t,ltl = 3.0 and diameter of disc d = 0.69 (b/a = 1.8125) the stress concentration is 1.92 near the hole and approaches to one at r/a equal to 10. This result agrees closely with the result presented by D. 0. McKenzie and J. P. H. Webbert for aluminum plate reinforced with a disc of CFRP. When the aluminum plate is reinforced with disc of CFRP and with the present reinforcement, the stress concentration is only 0.92, near the hole and approaches to one at the edge of the plate. Experimental results for all the same specimens are shown in Fig. 8. Stress concentrations are very close to the theoretical predictions. CONCLUSION The stress dist~bution around a hole in a finite isotropic plate reinforced by composite material, has been calculated, using finite element analysis hence stress concentration factor of 0.9,
4

A ALUMINUM
3D ALUMINUM 0 ALUMINUM 4

PLATE DISC DISC WINDING

0123456?89
R/A

10

II

Fig. 8. Experimental stress distribution of stress across-Minimum Section of Alum. plate, CFRP DISC-reinforced. Alum SCPresent Specimen. b,h = 1.8125, f,/t, = 3.0.

766

G. S. GIARE and R. SHABAHANG

is evaluated. The stress concentration factor using an experimental technique is 1.25. Results agree very closely with expe~mental investigations. The theoretical and experimental results have shown that the present reinforced around hoop-wound carbon fiber disc provides an efficient reinforcement around circular holes. This technique could be very useful in reducing the stress concentration factor of orthotropic plates of composite materials. The present reinforcement technique may be found to be particularly useful in composite laminate plates, where they could be incorporated during manufacturing process.
Acknowledgemenrs-The authors are thankful to Professor Blame Butler. Chairman, Aeronautical Engineering Department of Embry-Riddle Aeronautical University, for his encouragement and support. The authors are also thankful to Miss Santwana Giare for helping in testing and discussion. It is a pleasure to acknowledge the partial support of N.S.F. grant for the development of the composite laboratory at Embry-Riddle Aeronautical University.

REFERENCES [I] C. Gurney, An analysis of the stresses in a flat plate with a reinforced circular hole under edge forces. ARC R & M
1834 (1938). [2] H. Reissner and M. Morduchow. Reinforced circular cutouts in plane sheets. NACA TN 1852 (1949). [3] E. H. Mansfield, Neutral holes in plane sheet-reinforced holes which are elastically equivalent to the uncut sheet, Q, Jl Mech. appl. Math. VI, 370 (1953). [4] Elastic stress concentration factors single reinforced and unreinforced holes in infinite plates of isotropic materials. Engineering Sciences Data Unit, ESDU Item No 70005 (1970). [5] D. 0. McKenzie, and J. P. H. Webber, Aeronaut Q V 26 Pt. 4, p. 254-274 (November 1975). [6] S. G. Lekhnitskii, Anisoiropic Plates, 2nd edn, Chapter 6. Gordon and Breach, New York (1968). [7] G. S. Giare, Fracture toughness of unidirectional fibre reinforced composites in mode II. Engng Fracture ML& 20, I l-21 (1984).

(Received 29

February

1988)