<p>The introduction of carbon-fibre reinforced plastics in loadbearing automotive structures provides a great potential toreduce vehicle weight and fuel consumption. To enable themanufacture and assembly of composite structural parts,reliable and cost-effective joining technologies must bedeveloped. This thesis addresses several aspects of joining andload introduction in carbon-fibre reinforced plastics based onnon-crimp fabric reinforcement.</p><p>The bearing strength of carbon fibre/epoxy laminates wasinvestigated considering the effects of bolt-hole clearance.The laminate failure modes and ultimate bearing strength werefound to be significantly dependent upon the laminate stackingsequence, geometry and lateral clamping load. Significantreduction in bearing strength at 4% hole deformation was foundfor both pin-loaded and clamped laminates. The ultimatestrength of the joints was found to be independent of theinitial bolt-hole clearance.</p><p>The behaviour of hybrid (bolted/bonded) joints wasinvestigated both numerically and experimentally. Athree-dimensional non-linear finite element model was developedto predict the load transfer distribution in the joints. Theeffect of the joint geometry and adhesive material propertieson the load transfer was determined through a parameter study.An experimental investigation was undertaken to determine thestrength, failure mechanisms and fatigue life of hybrid joints.The joints were shown to have greater strength, stiffness andfatigue life in comparison to adhesive bonded joints. However,the benefits were only observed in joint designs which allowedfor load sharing between the adhesive and the bolt.</p><p>The effect of the environment on the durability of bondedand hybrid joints was investigated. The strength and fatiguelife of the joints was found to decrease significantly withincreased ageing time. Hybrid joints demonstrated increasedfatigue life in comparison to adhesive bonded joints afterageing in a cyclic freeze/thaw environment.</p><p>The strength and failure mechanisms of composite laminatessubject to localised transverse loading were investigatedconsidering the effect of the specimen size, stacking sequenceand material system. Damage was found to initiate in thelaminates at low load levels, typically 20-30% of the ultimatefailure load. The dominant initial failure mode wasintralaminar shear failure, which occurred in sub-surfaceplies. Two different macromechanical failure modes wereidentified, fastener pull-through failure and global collapseof the laminate. The damage patterns and ultimate failure modewere found to depend upon the laminate stacking sequence andresin system. Finite element analysis was used to analyse thestress distribution within the laminates and predict first-plyfailure.</p><p><b>Keywords:</b>Composite, laminate, bearing strength,joining, load introduction, hybrid joint, finite elementanalysis, mechanical testing.</p>

Several problems must be solved in the construction, design, and operation of a nuclear fusion reactor. One of the chief problems in the manufacture of high-powered copper/polymer composite magnets is the difficulty to precisely control the fiber volume fraction. In this thesis, the effect of variations in fiber volume fraction on thermal stresses in copper/cyanate ester composite cylinders is investigated. The cylinder is a composite that uses copper wires that run longitudinally in a cyanate ester resin specifically developed by Composite Technology Development, Inc. This composite cylinder design is commonly used in magnets for nuclear fusion reactors. The application of this research is for magnets that use cylindrical coil geometry such as the Mega Amp Spherical Tokamak (MAST) in the UK. However, most stellarator magnet designs use complex geometries including the National Compact Stellarator Experiment (NCSX), and the Quasi-Poloidal Stellarator (QPS). Even though the actual stresses calculated for the cylindrical geometry may not be directly applicable to these projects, the relationship between fiber volume fraction and stresses will be useful for any geometry. The effect of fiber volume fraction on stresses produced by mechanical, thermal and magnetic loads on cylindrical magnet coils is studied using micromechanics with laminate plate theory (LPT) and finite element analysis (FEA).Based on the findings of this research, variations in volume fraction do significantly affect the stress experienced by the composite cylinder. Over a range of volume fractions from 0.3 to 0.5, the LPT results demonstrate that thermally induced stresses vary approximately 30% while stresses due to pressure vary negligibly. The FEA shows that magnetic stresses vary much less at around only 5%. FEA results seem to confirm the LPT model. It was also concluded that the stress in the insulation layers due to all types of loadings is significant and must be considered when using this system in fusion applications.

This thesis focuses on the investigation of behavior of thick and moderately thick laminates under transverse and horizontal loading for different boundary conditions and configurations. An efficient finite element solution is proposed for analyzing composite laminates. Based on a combination of composite theory and 3-D Elasticity Theory, a 3-D finite element program is developed in MATLAB for calculating the stresses, strains and deformations of composite laminates under transverse and/or horizontal loading for different boundary conditions. The applicability of the formulation to analysis of laminated rubber bearings is also examined in this study. Since it is very important to calculate the correct stress state when developing models for composite behavior, the 3-D Elasticity Theory is used in this research. Numerical results are presented for various problems with different lamination schemes, loading and boundary conditions. In order to verify the analysis and the numerical calculations, numerical solutions obtained in this study are compared with available closed form solutions in the literature, experiment results and a commercial finite element program, namely ANSYS. The results obtained using the present finite element is found to be in acceptable and good agreement with the closed form solutions in the literature for thick and moderately thick rectangular and square plates.

Laminate flooring manufacturers have received negative feedback from customers on the sound quality of laminate flooring installations. Customers express a preference for the sound of traditional hardwood floors over that of laminate flooring composites. Consumers notice a difference between the sounds created by a footfall between laminate flooring and hardwood flooring. They perceive the laminate flooring sound of a footfall to be annoying and associate it to the flooring being of a lower quality. No objective test procedure exists to validate the marketing claims of the performance of these products. The objective of the work in this thesis is to develop a test method that evaluates the human perception of the sound quality of footfall noise on laminate flooring composites.

Low velocity impact behaviour of bi-layered laminates of acrylic and polycarbonate was investigated using a combination of drop tower impact experiments and explicit finite element analysis in LS-DYNA. Material characterisation tests were conducted in tension and in compression to obtain material properties for input to the material model in the numerical analysis. Quasistatic plate bending tests were conducted at different loading rates to compare the quasistatic response of the materials to the impact behaviour. Impact tests on circular plates of monolithic acrylic and polycarbonate were carried out using an instrumented drop weight impact tester. The impact force histories were recorded and a multiparameter approach was used to determine critical energy. Acrylic exhibited radial cracking, spalling and pene- tration while polycarbonate underwent large deformation and failed by dishing and plugging. The damage caused by impact in the bilayered laminate included partial or full delamination at the interface and radial cracks in the acrylic layer. The low velocity impact responses were simulated using 8-noded solid elements in LS- DYNA. A node-splitting technique based on maximum tensile stress failure criterion and an erosion approach based on maximum principal stress criteria was used to model the failure of acrylic. A material model that takes into account the asym- metric behaviour in tension and compression was investigated. The delamination between the acrylic and polycarbonate plate was modelled by a tiebreak contact with a shear strength based failure. The results of the finite element simulations are in good agreement with the experimental data.

Validerat; 20140915 (global_studentproject_submitter)

L’un des défis de la simulation numérique de la résistance au crash des structures composites est de pouvoir prédire les endommagements, leur évolution au cours de l’écrasement et l'énergie absorbée, à partir d'un nombre limité de propriétés matériau. Le but de cette étude est d'améliorer la compréhension des mécanismes élémentaires impliqués dans l'écrasement de stratifiés de plis unidirectionnels à base de fibres de carbone et de développer un modèle numérique. Des essais sont réalisés à différentes échelles (macro, micro), et conduisent à la définition d'une nouvelle propriété matériau, essentielle : la contrainte moyenne d'écrasement que peuvent soutenir les plis à 0° ou 90°, et la méthode de caractérisation associée. L’analyse des tests montre également que pour représenter correctement le comportement du matériau pendant le crash (évasement, fragmentation...), il est nécessaire de choisir un modèle à l’échelle méso. Le modèle éléments finis développé repose sur cinq idées principales : 1-mailler chaque pli; 2-utiliser des éléments cohésifs pour représenter le délaminage et l’évasement des plis; 3-pouvoir représenter la rupture des plis en gros fragments; 4-représenter l'écrasement localisé des plis, à leurs extrémités, par l'introduction d'un concept de « free-face-crushing », associé à un critère spécifique basé sur la contrainte moyenne d'écrasement; 5-représenter les contacts entre plis, plis etsocle, plis et débris. Ce modèle phénoménologique est ensuite appliqué à la simulation du crash de plaques stratifiées. A partir des propriétés matérielles élémentaires du pli, il permet de prédire la force, les principaux mécanismes de rupture et la phénoménologie observée lors des expériences. / A challenge in numerical simulation of crashworthiness is to be able to predict the crush damage modes, their evolution during crushing and the energy absorbed in any composite structure from a limited number of material properties. The aim of this study is to improve the understanding of the elementary mechanisms involved in the crushing of CFRP laminates made of unidirectional plies and to develop a numerical model. Crushing tests are performed at different scales (macro, micro), and lead to the definition of a new essential material property: the mean crushing stress that a 0° or 90° ply can support, and its associated characterization method. Tests analyses also show that to correctly represent the material behavior during crushing (splaying, fragmentation…) it is necessary to choose a mesoscale model. The Finite Element model developed in this thesis is based on five main ideas: 1-Meshing of each ply of the laminate; 2-Use of cohesive elements to represent delamination and plies splaying; 3-Possibility to represent failure of pliesinto big-sized fragments; 4-Representation of the localized crushing of plies, at their extremities, with the introduction of a free-face-crushing concept associated to a specific criterion based on the mean crushing stress; 5-Representation ofcontacts between plies, plies and impacted base, plies and debris.This physically based model is then applied to the simulation of the crushing of laminated plates. From elementary material properties of the ply, it allows to predict the force, the main failure mechanisms and the phenomenology observedduring crushing experiments.

O presente estudo tem como objetivo principal desenvolver um compósito cimentício reforçado com fibras de arumã. O intuito é agregar valor a uma planta típica da região Amazônica, denominada arumã, pertencente à espécie do gênero Ischnosiphon arouma (aubl) Korn e originária da família Maranthaceae, de tal modo que possa ser obtido um Novo Material. Na primeira etapa do estudo foi realizada a caracterização da fibra vegetal de arumã e de todos os componentes da matriz cimentícia, a qual compreendeu ensaios químicos, físicos e mecânicos para a investigação e avaliação de suas propriedades. Na etapa seguinte, adotou-se o procedimento de trabalhar as características físicas e mecânicas das fibras junto à matriz cimentícia, compreendendo um estudo da modificação superficial da fibra por meio de tratamentos químicos à base de soluções de hidróxido de sódio ou utilizando processos com água quente e hornificação. Na terceira etapa, foram produzidas placas reforçadas com fibras sem e com tratamento, as quais, parte delas foram submetidas à cura por 28 dias e as restantes ao ensaio de envelhecimento acelerado. Os resultados obtidos na caracterização das fibras de arumã indicam o seu potencial uso como elemento de reforço para compósitos cimentícios. Por outro lado, os compósitos produzidos com telas de fibra de arumã sem e com tratamento (hornificação e alcalino), apresentaram comportamento pouco dúctil e com baixa resistência, como consequência da degradação das fibras na matriz cimentícia. Isso foi confirmado por meio de ensaios de envelhecimento acelerado com ciclos de molhagem e secagem. / This present study aims to develop a cementation composite reinforced with arumã fiber. The aim is to aggregate value to a typical plant of the Amazon region, called arumã, belonging to species of the genus Ischnosiphon arouma (Aubl) Korn and originally from Maranthaceae family, so that, it can be obtained a New Material. In the first stage of the study was performed the characterization the vegetable fiber arumã and all components of the cementicious matrix, which comprised chemical, physical and mechanical tests for research and evaluation of their properties. In the next stage, it was adopted the procedure of working the physical and mechanical characteristics of the fibers with the cementitious matrix comprising a study of the surface of the fiber modification by chemical treatments using sodium hydroxide solution or employing procedures with hot water and hornification. In the third step, the reinforced plates were produced without and with treatment, which, part of were subjected to cure for 28 days and the remaining subjected to the accelerated aging test. The results obtained in the characterization of arumã fibers indicate its potential use as a reinforcement element for cementicious composites. On the other hand, the composites produced with arumã fiber fabrics without and with a treatment (hornification and alkaline) showed slightly ductile behavior and low strength as a result of degradation of fibers in the cementitious matrix. This was confirmed through accelerated aging tests with wetting and drying cycles.

This study focuses on developing novel modeling techniques for fiber-reinforced composites with polymer and ceramic matrix based on Peridynamic approach. To capture the anisotropic material behaviors of composites under quasi-static and dynamic loading conditions, a new peridynamic model for composite laminate and a modified peridynamic approach for non-uniform discretization are proposed in this study. In order to achieve the numerical implementation of the proposed model and approach, a mixed implicit-explicit solver based on GPU parallel computing is developed as well. The new peridynamic model for composite laminates does not have any limitation in fiber orientation, material properties and stacking sequence. It can capture the expected orthotropic material properties and coupling behaviors in laminates with symmetric and asymmetric layups. Unlike the previous models, the new model enables the evaluation of stress and strain fields in each ply of the laminate. Therefore, it permits the use of existing stress- or strain-based failure criteria for damage prediction. The computation of strain energy stored at material points allows the energy-based failure criteria required for delamination propagation and fatigue crack growth. The capability of this approach is verified against benchmark solutions, and validated by comparison with the available experimental results for three laminate layups with an open hole under tension and compression. The modified peridynamic approach for non-uniform discretization enables computational efficiency and removes the effect of geometric truncations in the simulation. This approach is a modification to the original peridynamic theory by splitting the strain energy associated with an interaction between two material points according to the volumetric ratio arising from the presence of non-uniform discretization and variable horizon. It also removes the requirement for correction of peridynamic material parameters due to surface effects. The accuracy of this approach is verified against the benchmark solutions, and demonstrated by considering cracking in nuclear fuel pellet subjected to a thermal load with non-uniform discretizations. Unlike the previous peridynamic simulations which primarily employs explicit algorithm, this study introduces implicit algorithm to achieve peridynamic simulation under quasi-static loading condition. The Preconditioned Conjugate Gradient (PCG) and Generalized Minimal Residual (GMRES) algorithms are implemented with GPU parallel computing technology. Circulant preconditioner provides significant acceleration in the convergence of peridynamic analyses. To predict damage evolution, the simulation is continued with standard explicit algorithms. The validity and performance of this mixed implicit-explicit solver is established and demonstrated with benchmark tests.

The present study considers the dependence of mechanical properties in composite laminates on the fibre architecture. The objective is to characterise the mechanical properties of composite plates while varying the fibre distribution but keeping the constituent materials unchanged. Image analysis and fractal dimension have been used to quantify fibre distribution and resin-rich volumes (RRV) and to correlate these with the mechanical properties of the fibre-reinforced composites. The formation, shape and size of RRV in composites with different fabric architectures is discussed. The majority of studies in literatures show a negative effect of the RRV on the mechanical behaviour of composite materials. RRV arise primarily as a result of (a) the clustering of fibres as bundles in textiles, (b) the stacking sequence, and/ or stacking process, (c) the resin properties and flow characteristics, (d) the heating rate as this directly affects viscosity and (e) the consolidation pressure. Woven glass and carbon/epoxy fabric composites were manufactured either by the infusion or the resin transfer moulding (RTM) process. The fractal dimension (D) has been employed to explore the correlation between fabric architecture and mechanical properties (in glass or/ carbon fibre reinforced composites with different weave styles and fibre volume fraction). The fractal dimension was determined using optical microscopy images and ImageJ with FracLac software, and the D has been correlated with the flexural modulus, ultimate flexural strength (UFS), interlaminar shear strength (ILSS) and the fatigue properties of the woven carbon/epoxy fabric composites. The present study also considers the dependence of fatigue properties in composite laminates on static properties and fibre architecture. Four-point flexural fatigue test was conducted under load control, at sinusoidal frequency of 10 Hz with amplitude control. Using a stress ratio (R=σmin/σmax) of 0.1 for the tension side and 10 for the compression side, specimens were subjected to maximum fatigue stresses of 95% to 82.5% step 2.5% of the ultimate flexural strength (UFS). The fatigue data were correlated with the static properties and the fibre distribution, in order to obtain a useful general description of the laminate behaviour under flexural fatigue load. The analysis of variance (ANOVA) technique was applied to the results obtained to identify statistically the significance of the correlations. Composite strength and ILSS show a clear dependence on the fibre distribution quantified using D. For the carbon fabric architectures considered in this study, the fatigue properties of composite laminates have significant correlations with the fibre distribution and the static properties of the laminates. The loss of 5-6 % in the flexural modulus of composite laminates indicates an increasing risk of failure of the composite laminates under fatigue loads. The endurance limits, based on either the static properties or the fibre distribution, were inversely proportional to the strength for all laminates.