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Composites: Part B
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a r t i c l e i n f o a b s t r a c t
Article history: The residual strength and fatigue life of CFRP (Carbon Fiber-Reinforced Plastic) composite structures with
Received 23 September 2013 impact damage were predicted by using the characteristic length of the composite with the hole corre-
Received in revised form 7 January 2014 sponding to the impact damage area. Since the specimen has a C-shaped structure that is different from
Accepted 13 January 2014
the shape of a standard specimen, the shape factor was obtained from the concentration of the plate spec-
Available online 24 January 2014
imen and that of the structure using finite element analysis. The fatigue life of composite structures with
impact damage can be predicted accurately by applying the prediction model, which takes into account
Keywords:
the residual strength after impact, the shape factor which considers geometric characteristics, and the
A. Carbon fiber
A. Prepreg
fatigue characteristics of virgin composites that have not been impacted to the model for strength deg-
B. Fatigue radation following impact.
B. Residual/internal stress Ó 2014 Elsevier Ltd. All rights reserved.
http://dx.doi.org/10.1016/j.compositesb.2014.01.024
1359-8368/Ó 2014 Elsevier Ltd. All rights reserved.
J.-M. Koo et al. / Composites: Part B 61 (2014) 300–306 301
2
rR rHR Di Ei 2. Evaluation of residual strength of CFRP composite structures
¼ 1 1:45 0:01 ð2Þ
ro DI Eth with impact damage
where rHR is the hole notch strength and DI and Di are the diameters 2.1. Residual strength test of CFRP composite structures with impact
of the impactor and the permanent impression, respectively. It was damage
reported that since the results predicted by Eq. (2) agree well with
the experimental results of CFRP composites, the residual strength This residual strength test was performed with WSN3K mate-
after impact can be estimated by measuring the size of the perma- rial, which is a plain-woven carbon prepreg with a thickness of
nent impression on the surface of the composite. 0.27 mm, made by Hankuk Carbon Co., Ltd. in Korea. The laminated
Whitney and Nuismer [18,19] proposed the point-stress crite- plate was molded for 60 min in an autoclave at a temperature of
rion (PSC) and average-stress criterion (ASC), which require evalu- 140 °C and pressure of 5.88 MPa, and the 16-ply fabricated lami-
ation of the characteristic length. Such a characteristic length is nate was 3.6 mm thick. The structure specimen was made into a
assumed to be a material property, independent of the hole size C shape as shown in Fig. 1, with dimensions W = 40 mm,
or geometry of the plate. However, Pipes et al. [20] proposed a H = 25 mm, L = 200 mm, and Hg = 20 mm. The chemical composi-
modified PSC model that assumes an exponential relationship be- tions of the prepreg are shown in Table 1 and the mechanical prop-
tween the characteristic length and the size of the discontinuity erties of specimens are shown in Table 2.
rather than regarding the characteristic length as a material con- The impact damage was applied to the center of the composite
stant. Also, Kim and Kim [21] reported the effects of hole size structures using a drop impact tester in which an impactor of 7 kg
and specimen width on the fracture behavior of woven glass and in mass drops with an initial velocity of 0 m/s, with a block in-
woven carbon fabric composites. Kim et al. [22] suggested a failure serted inside the body in order to implement the plane support
model for notch strength and characteristic length, considering the conditions (Fig. 2). The incident impact energy (Ei) of 23.5 J was ap-
effects of hole size and specimen width. plied using impactors 15.8 mm and 25.4 mm in diameter. Also, to
Broutman and Sahu [23] suggested a fatigue life prediction evaluate the residual strength after the impact of the C-shaped
model under block loading as a function of residual strength, on structure specimen, tensile tests were performed at room temper-
the basis of experimental observations that the residual strength ature at a speed of 3 mm/min using a universal testing machine
decreases as the number of fatigue loading cycle increases. When with a capacity of 250 kN (Instron, Co.).
a series of m fatigue blocks of cycle number ni at a maximum stress The residual strength tests after impact using an impactor
ri are applied, the residual strength rm is given by: 15.8 mm in diameter were performed three times (Fig. 3). The
measured residual strength values were 345–383 MPa, with mean
m
X
ro ri n i value 364.3 MPa. Similar tests using an impactor 25.4 mm in diam-
¼1 ð3Þ
i¼1
ro rm N i eter were performed twice. The residual strength values were 320–
373 MPa, with a mean value of 346.5 MPa.
where Ni is the fatigue life when ri is applied. They assumed that
failure occurs when the maximum cyclic stress exceeds the residual 2.2. Notch strength of a finite plate
strength. Hahn and Kim [24] reported that fatigue failure of com-
posites is not dictated by the initiation and growth of a dominant Whitney and Nuismer [18,19] assumed that failure occurs when
crack as in metallic materials, and assumed that the rate of residual the normal stress is equal to the fracture strength at a certain dis-
strength reduction is inversely proportional to the residual strength. tance from the tip of a discontinuity in a material. Also, the PSC is
From this assumption and the static strength distribution, they de- expressed as follows from the normal stress distribution at the tip
rived the fatigue life distribution. Whitworth [25] proposed a model of the hole:
for relating the residual strength of graphite/epoxy laminates to the
r1
N 2 R
applied fatigue cycles and the maximum applied stress. Based on ¼ ; g¼ ð4Þ
the model, the statistical distribution of the residual strength was
r0 2 þ g2 þ 3g4 ðK 1
T 3Þð5g 7g Þ
6 8 R þ d0
derived. Kang and Kim [26] introduced the strength reduction con- where r1 N is the notch strength for an infinite plate, do is the char-
cept, based on Broutman’s model under 2-stage loading, to describe acteristic length, R is the hole radius and K 1
T is the stress concentra-
the fatigue behavior of the impacted laminates. Also, Koo et al. [17] tion factor of an infinite plate:
assumed that damages by impact and fatigue are due to two-step vffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
u sffiffiffiffiffi !
block loading and proposed a prediction model in which the predic- u Ey Ey
K1 t
¼1þ 2 mxy þ ð5Þ
tion equation for the residual strength after impact is applied to the T
Ex Gxy
prediction equation for the fatigue life after impact.
In this study, in order to predict the residual strength of the
composite structures damaged by impact, the hole notched
strength was analytically predicted by applying the characteristic
length to the composite structures with the hole corresponding
to an impact damage area. Next, after the shape factor was ob-
tained from the concentration factor of a plate specimen and that
of the structure with the hole corresponding to an impact damage
area by finite element analysis, those factors were substituted into
the prediction model for the residual strength after the impact of
the CFRP composites [17], thereby computing the residual strength
based on the geometric characteristics. Also, the prediction model
for the residual strength after impact was applied to the prediction
model for fatigue life based on the residual strength reduction con-
cept, and the fatigue life was predicted and then verified against
the results of an actual fatigue test of composite structures with
impact damage. Fig. 1. Appearance of C-shaped structure specimen.
302 J.-M. Koo et al. / Composites: Part B 61 (2014) 300–306
rffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
h i
Table 1 3ð12R=WÞ
Chemical compositions of prepreg. 1 8 2þð12R=WÞ 3 1 1
M2 ¼ ð7Þ
Fabric wt. (g/m2) Resin wt. (g/m2) Resin content (%) Total wt. (g/m2) 2ð2R=WÞ2
205 148 42 ± 2 353
Kim and Kim [21] evaluated the notch strength as a function of the
width of a composite specimen and the hole size and suggested a
characteristic length as follows, considering the effects of hole size
Table 2
and specimen width.
Mechanical properties of prepreg.
m
Ex (GPa) Ey (GPa) gxy Gxy (GPa) 1 2R
d0 ¼ ð8Þ
55 55 0.13 4.75
k W
where k is a notch sensitivity coefficient related to 2R and W, and m
is the characteristic length change ratio (0 < m < 1). After Kim, et al.
[22] obtained the experimental relationship between the character-
istic length and notched strength of CFRP composites by regression
analysis, the relationship for an infinite plate was converted into the
following equation for a finite plate:
m
rN 1 d0 1 2R
¼ ; d0 ¼ ð9Þ
r0 Y 0:2R þ d0 k W
They reported that the constant of Eq. (9), m, is the material con-
stant and the value of k changes according to 2R/W [22]. In the pres-
ent study, the characteristic length was obtained using Eq. (9).
Here, Ex, Ey, Gxy and txy are the effective elastic moduli and Poisson’s
ratio of the laminate. If rN represents the notch strength for a finite
plate, the notch strength for an infinite plate r1 N can be expressed as
YrN, where Y is the finite plate correction factor. From Tan’s study
[27], the approximate finite width correction factor of composites
with a circular hole can be obtained by using Eq. (6).
" 6 #1
3ð1 2R=WÞ
1 2R 1 2R
Y¼ þ M ðK T 3Þ 1 M
2 þ ð1 2R=WÞ3 2 W W
ð6Þ
After stress analysis was performed for the standard plate specimen
with width (W) = 73 mm, thickness (t) = 3.5 mm, and hole notched
diameter = 6.4 mm, the shape factor of 0.879 was calculated from
the stress concentration factors for the standard plate specimen
with width = 73 mm and the C-shaped structure specimen in
Fig. 1 as follows:
K t;specimen 2:532
F¼ ¼ ¼ 0:879 ð12Þ
K t;structure 2:882
When this shape factor was substituted into Eq. (11), the residual
strength was about 379 MPa. The predicted result can be seen to
agree with the tested mean residual strength of the structure after
Fig. 5. Analysis results for a standard plate specimen [34]. impact (364.3 MPa), with a difference of about 14.7 MPa.
304 J.-M. Koo et al. / Composites: Part B 61 (2014) 300–306
If Eq. (16) is expressed as the fatigue life after impact, the result
Fig. 8. Specimen configuration. becomes:
J.-M. Koo et al. / Composites: Part B 61 (2014) 300–306 305
rR rmax For the case in which an incident impact energy of 10 J was in-
Ni ¼ Nf ð17Þ
ro rmax flicted on a CFRP composite structure by an impactor 15.8 mm in
diameter, the residual strength was predicted to be about
Hwang and Han [33] proposed the following equation as a fatigue
496 MPa using the characteristic length method described in Sec-
life prediction model for composite materials without impact:
tion 2.3. The prediction curve for fatigue life applying the predicted
rmax q hole notched strength to Eq. (21) agrees well with the actual test
Nf ¼ p 1 ð18Þ results for this case (Fig. 8).
ro
This result indicates that the fatigue life of CFRP composite
where p and q are material constants obtained from the fatigue structures with impact damage can be predicted accurately by
tests for composite materials without impact. From the fatigue test the combined application of the prediction model for the residual
results for composite materials without impact, the values obtained strength after impact, the shape factor considering the geometric
for p and q are 1.305 1011 and 9.815, respectively. If the prediction characteristics, and the fatigue characteristics of virgin composites
equation of Hwang and Han for the fatigue life of composite mate- without impact to the model of strength degradation due to impact
rials without impact [33] is applied to Eq. (17), the equation damage.
becomes:
q
rR rmax rmax 4. Conclusions
Ni ¼ p 1 ð19Þ
ro rmax ro
In this study, residual strength and fatigue characteristics were
If the residual strength prediction model of Eq. (2) is substituted predicted for the CFRP composite structures that received a dam-
into Eq. (19), the result is as follows: aging impact. The following results were obtained.
" 2 #
Di Ei rHR rmax ro
Ni ¼ 1 þ 1:45 þ 0:01 p (1) Using finite element analysis, the hole notched strength of a
D Eth ro ro rmax standard plate specimen, with the hole corresponding to an
rmax q area of impact damage, was acquired from the point-stress
1
ro criterion (PSC). The residual strength was calculated by
ð20Þ substituting the hole notched strength of a standard plate
specimen into the prediction model for the residual strength
In the case of composite structures, since the shape factor (F) should after impact. The predicted result agrees well with the
be considered, Eq. (20) becomes as follows; experimental result.
" 2 # (2) To apply s method for predicting residual strength using the
Di Ei F rHR rmax ro
Ni ¼ 1 þ 1:45 þ 0:01 p point-stress criterion (PSC) to a C-shaped structure, the
D Eth ro ro rmax shape factor obtained from the concentration factor of a
K
rmax q plate specimen and that of the structure, that is, F ¼ Kt;specimen
1 t;structure
ro was applied to the prediction model for the residual
ð21Þ strength. The predicted result agreed well with the experi-
mental result.
In this study, to evaluate the influence of the residual strength on (3) In this study, the following prediction model for fatigue life
the fatigue life of the standard plate specimen, the result of was proposed and the fatigue test results agreed well with
Eq. (20) and the result of substituting Eq. (1) from the prediction the fatigue prediction results.
model of Caprino [12,13] into Eq. (19) were compared to the fatigue
test results. The fatigue prediction from Eq. (20) agreed well with " 2 #
Di Ei F rHR rmax ro
the fatigue test results shown in Fig. 9. On the other hand, since Ni ¼ 1 þ 1:45 þ 0:01 p
D Eth ro ro rmax
the result from the fatigue prediction model applying Caprino’s q
model is located in the lower boundary area of the fatigue test rmax
1
ro
results (see Fig. 10), the fatigue prediction model applying Caprino’s
model produces slightly conservative results.
(4) The fatigue life of CFRP composite structures with impact
damage can be predicted accurately by the combined appli-
cation of a prediction model that takes into account the
residual strength after impact, the shape factor which con-
siders geometric characteristics, and the fatigue characteris-
tics of virgin composites that have not been impacted to the
model of the strength degradation due to impact damage.
Acknowledgments
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