Metallic robotic arms, or manipulators, currently dominate automated industrial operations, but due to their intrinsic weight, have limited usefulness for large-scale applications in terms of precision, speed, and repeatability. This thesis focuses on exploring the feasibility of using polymeric composite materials for the construction of long-reach robotic arms. Different manipulator layouts were investigated and an ideal design was selected for a robotic arm that has a 5 [m] reach, 50 [kg] payload, and is intended to operate on large objects with complex curvature. The cross-sectional geometry of the links of the arm were analyzed for optimal stiffness- and strength-to-weight ratios that are capable of preserving high precision and repeatability under time-dependent external excitations. The results lead to a novel multi-segment link design and method of production. A proof-of-concept prototype of a two degrees-of-freedom (2-DOF) robotic arm with a reach of 1.75 [m] was developed. Both static and repeatability testing were performed for verification. The results indicated that the prototype robot main-arm constructed of carbon fiber-epoxy composite material provides good stiffness-to-weight and strength-to-weight ratios. Finite element analysis (FEA) was performed on a 3-D computer model of the arm. Successful verification led to the use of the 3-D model to define the dimensions of an industrial-sized robotic arm. The results obtained indicate high stiffness and minimal deflection while achieving a significant weight reduction when compared to commercial arms of the same size and capability.

This work is devoted to the computational modeling of a lightning strike electric arc discharge induced air plasma and the material response under the lightning strike impact. The simulation of the lightning arc plasma has been performed with Finite element analysis in COMSOL Multiphysics. The plasma is regarded as a continuous medium of a thermally and electrically conductive fluid. The electrode mediums, namely the cathode and anode, have also been included in the simulation in a unified manner, meaning that the plasma and electrode domains are simulated concurrently in one numerical model. The aim is to predict the lightning current density, and the heat flux impinged into the anode's material surface, as well as the lightning arc expansion and pressure and velocity of the plasma flow. Our predictions have been validated by the existing experimental data and other numerical predictions reported by former authors.

A l'heure actuelle le stockage de l'hydrogène sous forme gazeuse, comprimée à haute pression, apparaît comme la solution le plus mature présentant le meilleur compromis en termes de masse, de pression de service mais aussi de volume des réservoirs. Cependant pour un développement plus large et sécurisé, l'amélioration des performances et la réduction des coûts des réservoirs restent des enjeux prioritaires. C'est dans ce contexte que nous avons étudié le stockage de l'hydrogène dans des réservoirs de type IV, en composites fibres de carbone/époxy. Ce travail a eu pour objectif d'accroitre la fiabilité du dimensionnement. Dans un premier temps, une étude expérimentale de caractérisation des matériaux constitutifs du réservoir a été réalisée. Pour améliorer la fiabilité des calculs, un modèle probabiliste a été proposé pour décrire le comportement de la partie composite du réservoir, principalement la rupture des fibres. Des calculs multiéchelles ont été mis en place basés sur les propriétés mécaniques et physiques des fibres. Les autres modes de dégradations, décollement entre plis, liaison embase-liner ont aussi été pris en compte dans les calculs de comportement du réservoir jusqu'à son éclatement. Enfin des recommandations de dimensionnement du réservoir ont été proposées afin d'améliorer les performances tout en minimisant la masse de composite dans un objectif de réduction des coûts. / Presently, the compressed hydrogen storage under high pressure appears to be the most sophisticated solution regarding to a compromise of mass, service pressure and also volume of pressure vessels. However, the challenges of pressure vessels nowadays are their performance improvement as well as their cost reduction. In this context, we studied the type IV hydrogen storage pressure vessel in carbon fibre/epoxy composites. This work aims to obtain a reliable pressure vessel design. Firstly, an experimental study of associated materials and pressure vessel characterisation has been carried out. Then, we proposed a probabilistic model for a composite which is dedicated in particular to fibre breakage using multi-scale simulations in accordance with its mechanical and physical properties. Once this model joined with damage criteria dedicated separately to the others damage mechanisms are integrated into the pressure vessel simulations. Finally, recommendations on composite pressure vessels have been proposed in order to improve their performances and to decrease the mass of composite directly corresponding to the reduction of composite pressure vessels cost.

Cette thèse est une contribution à la compréhension du comportement des composites carbone-époxy en compression par l’étude de l’influence des constituants (fibres et matrices). L’incidence d’un chargement mécanique d’amplitude constante ou variable sur la durabilité est étudiée et un modèle numérique permettant la prédiction de la résistance résiduelle est proposé. Une première partie des travaux s’intéresse aux mécanismes spécifiques engagés dans la résistance en compression. Un modèle analytique est retenu pour une confrontation expérimentale. Ce modèle propose de considérer d’une part le micro-flambage de la fibre comme contenu par le comportement en cisaillement de la matrice (Budiansky et Fleck, 1993). En complément, une partie supplémentaire de structure considérant, entre autres, l’influence du gradient de déformation induit dans une sollicitation en flexion 4 points est étudiée (Grandidier, 2002). Afin de valider la pertinence du modèle, une campagne expérimentale est menée sur six matrices époxy différentes (de fragile à ductile) dans des empilements stratifiés monolithiques identiques réalisés en cuisson autoclave. Ces résultats ont permis de valider la capacité du modèle à prédire l’influence de la rigidité de la matrice sur la résistance en compression. Le partie micro-flambage est validée pour la prise en compte de la matrice. La partie effet de structure (gradient ici) est validée par une comparaison avec des résultats supplémentaires obtenus sur des éprouvettes sandwich sollicitées en flexion. Ces dernières éprouvettes ont fait l’objet d’une conception spécifique afin de favoriser la rupture en compression pure (sans gradient de déformation). Une seconde partie est consacrée à l’étude de la durabilité en compression. Une campagne expérimentale d’essais de fatigue est menée en flexion 4 points sur les éprouvettes sandwich précédemment conçues. Les essais sont conduits à une fréquence de 10 Hz et différents rapports de charge dans une optique de dégager l’évolution de la résistance résiduelle. Un modèle numérique de changement d’échelles (stratifié, plis, constituants) est parallèlement développé, basé sur la dégradation et la plasticité de la matrice. On fait l’hypothèse de simplicité thermo-rhéologique de la matrice pour établir des courbes de maitresses à partir d’une série d’essais identifiés (fluage, relaxation, fatigue…). On utilise les propriétés résiduelles du pli (rigidité, résistance) pour estimer un indicateur d’endommagement. Ce dommage est répercuté dans les propriétés de la matrice au moyen d’une loi de dégradation linéaire. Une loi de cumul de dommage de type Miner est alors introduite pour tenir compte de la variabilité des chargements appliqués. Un solveur micro- mécanique est développé pour extraire le comportement non-linéaire du pli en cisaillement tenant compte de la dégradation. Ce comportement est paramétré par une loi de Ramberg-Osgood utilisée dans le modèle analytique validé précédemment. Les travaux des deux parties permettent donc la mise en place d’un outil de prédiction de la résistance résiduelle des plis sollicités dans un chargement biaxial plan, avec en particulier le traitement de la compression / This PhD dissertation is a contribution to the modelling of Carbon-Fiber-Epoxy-Polymer laminates, undergoing specifically compression loadings, according to components. The aim is to build a design tool for composites structures taking into account this compression specificity for dimensioning racing yachts parts (masts, daggerboards, foils), which is the expertise of HDS/GSea-Design, the company associated to this work. Emphasis was put on the influence of linear or non-linear properties of each phase by varying the type of fibre (from high stiffness to high strength) and the type of matrix (from brittle to ductile). The effect of a mechanical loading, static, constant (creep, relaxation) or variable (fatigue) on durability is studied and a numerical model for predicting the residual strength is proposed. The first part of this work deals with the mechanisms involved in compressive strength. An analytical model is used for an experimental validation. It considers a contribution linked to the micro-buckling of the fibre as contained by the shear behaviour of the matrix (Budiansky et Fleck [1993]). It considers also a contribution of the deformation gradient induced for instance in a bending loading (Gardin et al. [2002]). To validate this model, an experimental campaign was conducted on six different epoxy matrices (from brittle to ductile) on identical monolithic stackings processed in autoclave. The results allowed the validation of the model capability to predict the influence of the matrix stiffness on the compressive strength of unidirectional laminas. Taking into account the matrix behaviour validates the micro-buckling contribution. Regarding the deformation gradient contribution, it is validated through a comparison using additional experimental results on sandwich samples in bending. The latter samples were specifically designed to favour a pure compression fracture (without any deformation gradient). The second part examines durability in compression. Another experimental campaign with fatigue tests was conducted with four points bending tests on the same sandwich samples. Experiments were carried out at 10 Hz and different load ratios were used to study their influence on the compressive residual strength. A numerical model involving different scales (laminate, laminas, fibres and matrix) is developed in parallel (Huang et al. [2012a]), based on the degradation and the plasticity of the matrix. The assumption of thermo-rheological simplicity of the matrix is made to build master curves from dedicated experiments (creep, relaxation). We then use the residual properties (stiffness, strength) of the ply to estimate a damage level. This latter parameter is used to modify the elastic stiffness of the matrix with a linear law. A Miner-type cumulative law is used in fatigue to take into account the different possible loadings. A micro-mechanical solver is developed to extract the non-linear shear behaviour of the ply accounting for this degradation. This behaviour is described by a Ramberg-Osgood law used in the analytical model described in the first part of this work. The joint contributions of these two parts allowed us to program a numerical tool for predicting the residual strength of plies undergoing a biaxial in- plane loading, being monotonous, constant or with a variable amplitude, with emphasis on the particular case of compression loading.

The manufacture, laminate design, and modeling of a part with complex geometry are explored. The ultimate goal of the research is to produce a model that accurately predicts part stiffness. This is validated with experimental results of composite parts, which refine material properties for use in a final prototype part model. The secondary goal of this project is to explore manufacturing methods for improved manufacturability of the complex part. The manufacturing portion of the thesis and feedback into material model has incorporated a senior project team to perform research on manufacturing and create composite part to be used for experimental testing. The senior project was designed, led, and managed by the author with support from the committee chair. Finite element modeling was refined using data from coupon 3-point bend testing to improve estimates on material properties. These properties were fed into a prototype part model which predicted deflection of composite parts with different layups and materials. The results of the model were compared to experimental results from prototype part testing and 3rd party analysis. The results showed that an accurate mid-plane shell element model could be used to accurately predict deflection for 2 of 3 experimental parts. There are recommendations in the thesis to further validate the models and experimental testing.