A simplified model is proposed to investigate the stress fields and the strain energy release rate (SERR) associated with cracks in bonded joints in wind turbine blades. The proposed two-dimensional model consists of nonparallel upper and lower shells with adhesive between the shells at the tapered end. Nonlinear finite element analysis (FEA) is performed in a systematic parametric study of material and geo- metric properties. Two failure modes and their locations are predicted at different combinations of parameters: yielding at the outside end of the adhesive and interface cracking at the inside end of the bondline. Effect of the shell curvature on the stress fields is also considered. Based on the classic beam theory and the beam-on-elastic-foundation (BOEF) assumption, stress and displacement fields of the adhesively-bonded joint were determined by a new theoretical model to support the results from the numerical computation. The failure analysis is continued by studying the effects of manufacturing defects in the adhesive bond. Single and multiple voids are embedded to simulate air bubble trapped in the interface. The numerical and analytical studies are conducted to investigate SERR associated with the voids and results are provided to illustrate the effects of void position and void size.

Simulations using the Finite Element Method (FEM) play an increasingly important role in the design process of joints and fasteners in the aerospace industry. In order to utilize the potential of such adhesive bonding, there is an increasing need for effective and accurate computational methods. The geometry and the nature of an adhesive joint are, however, not so simple to describe effectively using standard FEM-codes. To overcome this difficulty, special FEM-elements can be developed that provide a material surface treatment of the adhesive and the joined parts. In order to create a model that reflects the above features, one may introduce proper scalings on the geometry and on the material properties in terms of a perturbation parameter. Within the framework of three-dimensional elasticity, together with an asymptotic expansion method, a material surface model is obtained through a systematic procedure. In such a derivation, no a priori assumptions for the displacements or stress fields are needed. The final result is a variational equation posed over a single reference surface which forms the basis of a structural element for the compound joint. Through the usage of continuum damage mechanics and the framework of a generalized standard material, the linear elastic model is extended to include an elastic-plastic material model with damage for the adhesive. The model is FE-discretized and an important implication is that the (quasi-static) propagation of the local failure zone in the adhesive layer can be simulated. The failure load is obtained as a computational result and consequently no postulated failure criterion is needed. The derived FE-method opens up the possibility to efficiently model and analyze the mechanical behavior of large bonded structures. / At the time the thesis was defended paper I. was in fact two manuscripts, which later were combined to give the published article.

In response to serious environmental and economic concerns, the design and production of aircrafts have been changing profoundly over the past decades with the nose-to-tail switch from metallic materials to lightweight composite materials such as carbon fibre reinforced plastic (CFRP). In this context, the present doctoral research work aimed to contribute to the development of a CFRP booster casing, a real innovation in the field initiated and conducted by Safran Aero Boosters. More specifically, this thesis addresses the matter of joining metal/CFRP hybrid structures, which are prone to possibly detrimental residual stresses.The issue is treated with an approach combining experimental characterisation and finite element (FE) simulations. The multi-layered system’s state of damage was systematically examined on hundreds of micrographs, and the outcome of this study is presented under the form of a statistical analysis. Further, the defects’ 3D morphology is investigated by incremental polishing. A number of thermal and mechanical properties are measured by diverse physical tests on part of the constituent materials, i.e. the aerospace grade RTM6 epoxy resin, the structural Redux 322 epoxy film adhesive, and AISI 316L stainless steel. They are used as input data in a FE model of the multilayer that is developed and progressively refined to obtain detailed residual stress fields after thermal loading. These results are compared to experimental data acquired by X-ray diffraction stress analysis and with the curvature-based Stoney formula. Cohesive elements are placed at specific locations within the FE model to allow simulating progressive damage. Peel tests, mode I, mode II and mixed mode I/II fracture tests are thus performed in view of measuring the joint toughness. The results of these tests are discussed and the presence of residual stress in the fracture specimens is highlighted. Key information for the calibration of the cohesive law is finally identified via inverse FE analysis of the mode I test, this being a significant step in the process of building a damage predictive FE model of the multi-layered system. / Doctorat en Sciences de l'ingénieur et technologie / info:eu-repo/semantics/nonPublished