复合材料单面修补板裂纹尖端J积分的解析预测模型

考虑附加弯矩的影响,基于单搭接接头理论建立了单面修补含中心穿透裂纹直板解析模型,求解了修补结构基板的最大最小应力,并与有限元结果进行对比验证,研究了补片长度、宽度、厚度和胶层弹性模量对有限元模型裂纹尖端J积分的影响,通过拟合基板应力与有限元模型裂纹尖端J积分的数值关系,得到了求解修补结构裂纹尖端J积分的解析公式,并验证了其在单面修补弯曲板的适用性。通过研究和分析发现,求解的解析模型适用于承受面内载荷、面外载荷以及混合载荷下的平板和弯曲板修补结构。     

复合材料胶结修补缺损金属结构的力学性能研究

进行了未修补与复合材料胶结修补的含穿透性裂纹金属试样的力学性能实验,测定了失效载荷,并分析了失效机理;采用实体层单元模拟复合材料补片和胶层,建立了复合材料胶接修补缺损金属结构的三维有限元分析模型,数值模拟了两种试样的载荷-位移曲线和应力分布,预测了破坏位置,与实验现象吻合良好。研究发现,与未修补的试样相比,经复合材料修补后的缺损结构承载能力得到明显提高。     

金属裂纹板复合材料胶接修补强度的弹塑性有限元预测

金属裂纹板经复合材料补片胶接修补后,其结构强度明显提高,但裂纹板中的裂纹会导致严重的应力集中现象,并易产生塑性变形,呈现强烈的材料物理非线性特性,需要采用弹塑性力学原理,进行复合材料胶接修复结构的静强度预测。为此,考虑金属板材料的非线性特性,建立了金属裂纹板复合材料胶接修补结构的弹塑性有限元模型,并通过试验验证了模型的有效性。在此基础上,提出了基于裂纹尖端的张开位移(COD)判据的拉伸强度预测方法,分析了修复结构的塑性应变、COD以及静拉伸强度。结果表明:相对于应力强度因子K判据, COD判据能更有效地预测修复试件的静拉伸强度。      

金属裂纹板复合材料修补结构的超奇异积分方程方法

根据应力强度因子在线弹性范围内具有可叠加性,将金属裂纹板复合材料修补结构进行简化,在表面裂纹线弹簧模型的基础上,建立了基于超奇异积分方程的Line-Spring模型。利用第二类Chebyshev多项式展开的方法,将超奇异积分方程转化为线性方程组,推导出以裂纹面位移表示的应力强度因子表达式,得到了裂纹尖端应力强度因子的数值解,并利用虚拟裂纹闭合法加以验证。参数分析确定了影响对称修补裂纹板应力强度因子的两个主要参数:胶层界面刚度和补片与金属板刚度比,为胶接修补结构的承载能力分析以及改进设计提供理论依据。     

基于全试验设计方法的含裂纹铝合金板复合材料修补参数优化

建立含穿透裂纹铝合金板复合材料单面胶接修补板条的三维有限元模型,基于位移外推法对裂纹尖端的应力强度因子(SIF)进行求解。使用全试验设计的方法对不同修补参数下修补板条的单向拉伸试验进行仿真模拟,利用二次方程描述并研究了补片长度、补片厚度及胶层弹性模量共同作用时对SIF的影响,确定了以SIF为评价指标时对修补效果影响最大的修补参数,优化了修补设计,并应用优化修补参数进行单向静拉伸试验。结果表明,当三类修补参数共同作用时,补片长度对修补效果影响最大;使用优化修补参数单面修补试验件的破坏强度比未修补板的提高了12.1%,恢复到完好板的90.5%。     

铝合金裂纹板的阳极化处理与复合材料补片胶接修理效果

采用磷酸阳极化方法对胶接修理铝合金裂纹板的粘接表面进行了处理,并用单向碳纤维/环氧复合材料补片对铝合金进行了修补.测试了阳极化铝合金的粘接性能、修补结构的静态力学性能和疲劳性能,考察了粘接表面的阳极化处理对修补结构的静态力学性能和疲劳性能的影响.结果表明,磷酸阳极化在铝合金表面形成多孔膜,复合材料补片修补胶接时胶粘剂能渗透进入阳极化铝合金表面的多孔膜,在粘接界面上形成一层过渡层,该过渡层的形成能有效提高其与复合材料的粘接性能,其粘接副的拉剪强度提高了104%;铝合金裂纹板胶接修理前的粘接表面的阳极化处理能大幅度地提高修复结构的静态强度和疲劳寿命,当用单向碳纤维/环氧复合材料补片单面修补时,修补结构的破坏强度为418.13MPa,恢复到完好板的93.42%;修补结构的疲劳寿命相对裂纹板延长了1.42倍,比未阳极化的修补板的疲劳寿命增加了27.59%.修补前的阳极化处理也使修补结构在一定周次疲劳后的剩余强度有所提高.     

纤维增强复合材料胶接结构疲劳特性研究进展

纤维增强复合材料胶接结构的疲劳特性与纤维、环氧树脂以及胶黏剂的特性紧密相关,为了开展复合材料胶接结构的疲劳性能研究,本文提出适用于复合材料胶接结构的疲劳分析方法,完成复合材料胶接结构的抗疲劳设计,从复合材料层压板、层间以及胶接界面等研究对象的疲劳特性分析方法入手,全面综述了国内外学者在复合材料结构、金属胶接结构以及复合材料胶接结构的疲劳特性及寿命预测方法等方面的研究进展.结果表明:采用S-N曲线拟合得到寿命预测模型对复合材料胶接结构进行寿命预测是行之有效的,以此为依据开发基于物理机制的有限元寿命预测模型可以对疲劳裂纹扩展及疲劳特性进行分析,对于层间损伤和界面损伤,多采用粘聚区模型进行模拟分析,可以为复合材料胶接结构的疲劳失效分析方法的建立提供指导.     

改进的复合材料斜接结构胶层应力半解析法

引入微分概念和复合材料铺层刚度分配原则,形成一种改进的求解复合材料斜面对接结构胶层应力的半解析方法 MAM(Modified semi-Analytical Method)。首先,针对铺层角度及铺层数不一致的情况,采用有限元法(FEM)平面应变模型对MAM进行验证;然后,分别用平均剪应力法、FEM及MAM预测了复合材料斜接结构的承载能力并与试验值进行对比;最后,利用MAM分析工程应用问题,考虑了被粘结体刚度不匹配及胶层厚度的变化。研究结果表明:MAM适于设计复合材料斜接结构;采用MAM能得到胶层应力的尖峰值,且应力分布与FEM计算一致。     

复合材料胶接修补结构的热应力分析

针对复合材料补片胶接修补损伤金属结构中存在的残余热应力，本文充分考虑了周期结构对胶接修补区域的约束作用，系统地分析了胶接修补结构中残余应力大小以及残余热应力对结构静强度和疲劳寿命的影响，所得结果将为实际结构的胶接修补提供依据。     

单向拉伸条件下补片参数对复合材料胶接修复结构的影响

建立含中心半穿透圆孔的损伤金属板修补结构的三维有限元模型,以应力集中系数(Stress Concentration Factor,SCF)和挠度w作为复合材料胶接修复效果的指标,分析单向拉伸条件下,正方形补片的长度、厚度和铺层方式对修复效果的影响。结果表明:补片长度取孔直径的3.5倍、厚度取孔深度的0.6~0.8倍、铺层方式取0°/90°铺层时,复合材料单面修复含损伤裂纹板的效果较好。根据分析结果制备了实验件,进行了单向静拉伸实验,修补实验件的破坏强度比未修补实验件提高了10.1%。     

An analytical solution for the analysis of symmetric composite adhesively bonded joints

Analytical solutions for adhesively bonded balanced composite and metallic joints are presented in this paper. The classical laminate plate theory and adhesive interface constitutive model are employed for this deduction. Both theoretical and numerical (finite element analysis) studies of the balanced joints are conducted to reveal the adhesive peel and shear stresses. The methodology can be extended to the application of various joint configurations, such as single-lap and single-strap joints to name a few. The methodology was used to evaluate stresses in several balanced adhesively bonded metallic and composite joints subjected to the tensile, moment and transverse shear loadings. The results showed good agreements with those obtained through FEM.     

复合材料夹芯管胶接连接结构力学特性分析

针对在航空结构中广泛应用的复合材料蜂窝夹芯圆管中的接头这一最脆弱的部分,发展了一种分析复合材料蜂窝夹芯圆管胶粘接头力学特性的解析模型.该模型根据Gibson修正公式得到了蜂窝芯子的等效弹性参数,再运用经典的复合材料壳理论和线弹性理论得到管接头的控制方程,并通过状态空间法进行求解.运用本文模型,计算了管接头在扭矩和弯矩作用下胶层内的剪应力和剥离应力;同时采用有限元法对模型进行了数值模拟,并将模拟结果与模型计算结果进行了对比,最后分析了搭接长度对胶层内应力的影响.     

Elasto-plastic stress analysis in an adhesively bonded single-lap joint

In this study, an analytical elasto-plastic stress analysis was proposed to determine the shear stress in a ductile adhesively bonded single-lap joint. DP460 adhesive was employed in the present study. The von-Mises criterion was used for checking the yield condition of the adhesive material. In the solution, the shear stress was assumed to be constant across the thickness of the adhesive. Bending moment was neglected in the solution. Analytical results were checked by using the finite element analysis. ANSYS 10 was employed in the numerical solution. Analytical and numerical solutions are found to be in a good agreement.     

Boundary element analysis of flat cracked panels with adhesively bonded patches

Adhesively bonded patch repairs for cracked finite sheets are analysed by the boundary element method. The interaction between the plate and the patch on a repaired sheet is modelled as a distribution of forces which include in-plane, out-of-plane and two moment body forces. The coupled boundary integral formulations of shear deformable plate (Mindlin theory) and two-dimensional plane stress elasticity are presented. Stress intensity factors, three for the bending problem and two for the membrane problem, are evaluated from crack opening displacements. Several examples are presented to demonstrate the accuracy and efficiency of the proposed method. Comparison with two-dimensional solutions demonstrate the significance of the bending loads on the stress intensity factors.     

Thermal and geometrically non-linear stress analyses of an adhesively bonded composite tee joint

Adhesive bonding technique is used successfully for joining the carbon fibre reinforced plastics to metals or composite structures. A good design of adhesive joint with either simple or more complex geometry requires its stress and deformation states to be known for different boundary conditions. In case the adhesive joint is subjected to thermal loads, the thermal and mechanical mismatches of the adhesive and adherends cause thermal stresses. The plate-end conditions may also result in the adhesive joint to undergo large displacements and rotations whereas the adhesive and adherends deform elastically (small strain). In this study, the thermal and geometrically non-linear stress analyses of an adhesively bonded composite tee joint with single support plus an angled reinforcement made of unidirectional CFRPs were carried out using the non-linear finite element method. In the stress analysis, the effects of the large displacements were considered using the small displacement–large displacement theory. The stress states in the plates and the adhesive layer of the tee joint configurations bonded to a rigid base and a composite plate were investigated. An initial uniform temperature distribution was attributed to the adhesive joint for a stress free state, and then variable thermal boundary conditions, i.e. air flows with different velocity and temperature were specified along the outer surfaces of the tee joints. The thermal analysis showed that a non-uniform temperature distribution occurred in the tee joints, and high heat fluxes took place along the free surfaces of the adhesive fillets at the adhesive free ends. Later, the geometrical non-linear thermal-stress analysis of the tee joint was carried out for the final temperature distribution and two edge conditions applied to the edges of the vertical and horizontal plates (HP). High stress concentrations occurred around the rounded adherend corners inside the adhesive fillets at the adhesive free ends, and along the adhesive–composite adherend interfaces due to their thermal–mechanical mismatches. The most critical joint regions were adhesive fillets subjected to high thermal gradients, the middle region of HP, the region of the vertical plate corresponding to the free end of the vertical adhesive layer–left support interface. In addition, the support length had a small effect of reducing the peak stresses at the critical adherend and adhesive locations.     

Adhesively-bonded joints in metallic alloys, polymers and composite materials: Mechanical and environmental durability performance

The factors affecting the mechanical and environmental durability (or stability), and performance of the adhesively bonded joints in various adherends including metallic alloys, polymers and composite materials are studied in detail. The primary function of a joint is to transfer load from one structural member to another. In most bonded joints the load transfer takes place through interfacial shear. At present, the use of adhesive bonded joints are largely applied to secondary non-critical structures. Whereas the use of adhesive bonding in primary structural applications has been somewhat limited because of the difficulty in defining and predicting joint strength, and designing the joint geometry to optimize strength and reliability. The determination of adhesive joint strength is complicated primarily by the nature of the polymeric material itself. Since these problems are mainly mechanical in nature, stress analysis is required to understand how the force loads are distributed along the adherends and adhesive layer. Most structural engineers consider the durability or stability of a joint to be fatigue related. This is only partly true for adhesive bonds as most durability issues are driven by environmental resistance rather than fatigue loads. The environmental resistance of an adhesive bond is determined by the chemical bonds formed during cure of the adhesive and the resistance of the chemical bonds to environmental degradation. Environmental resistance is fundamental to the durability of a bonded joint or repair. Most in-service failures are caused by environmental degradation of the interface between the bonding surface and the adhesive. Although the use of adhesive bonding is increasing rapidly, there are still important issues which need to be addressed in joint analysis, design, durability, and performance considerations. Therefore, the study of joints usually involves consideration of (a) joint geometries, (b) materials (i.e., adhesives and adherends), (c) loading conditions (i.e., static and dynamic loadings), (d) failure modes (i.e., cohesive, adhesive or mixed failure modes), and (e) temperature and moisture or environmental effects (humidity, solvents, corrosion, temperature extremes, thermal cyling etc.). Therefore, in the present paper the adhesive joints are critically assessed in terms of these factors which affect the durability and performance of them.There are two basic mathematical approaches for the analysis of adhesively bonded joints: (a) closed-form or analytical model and (b) numerical solutions (i.e., finite element analysis, FEA). In the closed-form approach, a set of differential equations and boundary conditions is formulated. The solutions of these equations are analytical expressions which give values of stresses at any point of joint. The analytical approach for the solution of complex stress distributions in the joints has been progressively refined until recent times. In the second approach, solutions of differential equations are obtained by numerical methods or the continuum is represented by a discrete model at the outset. The solution of these equations gives displacements at the determined points from which strains and stresses can be obtained for any point within the model. Among the numerical methods, finite element analysis (FEA) has been extensively used with success. The two- and three-dimensional finite element analyses approaches have been extensively applied by many workers to analyse the adhesive joints considering the linear and geometric nonlinearities.     

Proposed design chart of mechanical joints on steel-PHC composite piles

A fundamental study of a mechanical joint in a steel-PHC composite pile subjected to combined loads was done using three-point bending tests and 3D finite element analyses. The three-point bending tests were conducted to evaluate load-deformation response, strain distribution on the pile, ultimate bending moment and failure mode of the mechanical joint on steel-PHC composite piles. In addition, 3D finite element analysis for the mechanical joint was performed and then, the stress distributions and the maximum load resistances of each parts of the joint were estimated by comparing the calculated stresses to the yielding stresses of the joint materials. The 3D numerical methodology in the present study represents a realistic mechanism of mechanical joints. Through detailed numerical analysis, it is found that the behaviour of mechanical joint of composite piles shows safe side under working load. Based on these results, the design chart for steel-PHC piles has been proposed to be convenient for preliminary design stage which can be used to evaluate the safety of mechanical joints.     

Fatigue life estimation of adhesive bonded shaft joints

Fatigue tests and analytical investigation of adhesive bonded shaft joints were conducted to propose the estimation method of fatigue strength. Two kinds of adhesive bonded joints were studied: one, shaft joints connected with adhesive coupling, the other, adhesive joints of thin wall tubes to obtain standard fatigue strength. Both pulsating tensile and torsional fatigue tests were conducted with each adhesive joint. Furthermore, the stress distributions under tensile and torsional load conditions were analyzed by finite element method. Based on the analytically computed maximum normal shear stress in the adhesive layer, fatigue strength of the shaft joints was tandardized and compared with that of adhesive joints of thin wall tubes. As a result, it is confirmed that the maximum normal and shear stresses are key parameters for estimating fatigue strength under pulsating tensile and forsional load conditions, respectively. Furthermore, this study indicates an improved method of estimating fatigue strength by using tapered coupling order to reduce the stress concentration at the end of the adhesive layer.     

Stress-function variational method for stress analysis of bonded joints under mechanical and thermal loads

High interfacial stresses near the ends of adherends are responsible for debonding failure of bonded joints used extensively in structural engineering and microelectronics packaging. This paper proposes a stress-function variational method for determination of the interfacial stresses in a single-sided strap joint subjected to mechanical and thermal loads. During the process, two interfacial shear and normal (peeling) stress functions are introduced, and the planar stresses of adherends of the joints are expressed in terms of the stress functions according to the static equilibrium equations. Two coupled governing ordinary differential equations (ODEs) of the stress functions are obtained through minimizing the complementary strain energy of the joints and solved explicitly in terms of eigenfunctions. The stress field of the joints based on this method can satisfy all the traction boundary conditions (BCs), especially the shear-free condition near the adherend ends. Compared to results based on finite element method (FEM) and other analytic methods in the literature, the present variational method is capable of predicting highly accurate interfacial stresses. Dependencies of the interfacial stresses upon the adherend geometries, moduli and temperature are examined. Results gained in this study are applicable to scaling analysis of joint strength and examination of solutions given by other methods. The present formalism can be extended conveniently to mechanical and thermomechanical stress analysis of other bonded structures such as adhesively bonded joints, composite joints, and recently developed flexible electronics, among others.     

An adhesively laminated plate element for PZT smart plates

An adhesively laminated element taking into consideration peel stress is developed for a piezoelectric smart plate. In this novel finite element analysis formulation, a four node piezoelectric element is firstly derived, and an adhesive element of finite thickness with both shear and peel stiffness is sandwiched between two collocated four node plate elements to form an adhesively laminated element for a piezoelectric smart plate. In this framework of finite element analysis, because the displacement filed in this adhesively laminated element is continuous and a plate element is derived based on the Reissner–Mindlin plate theory, and thus it can be accurately applied to a thin or moderately thick host plate with bonded or debonded piezoelectric actuators and sensors. The formulation is performed for an isotropic host plate and a fiber reinforced laminate plate. Numerical results are presented to compare with those of the exact solutions for smart beams, and validate with the experimental results of the isotropic and composite host plates available in the literature. Using the present finite element analysis formulation, energy transfer stresses in the adhesive and equivalent forces induced in the host plate are investigated. The present formulation is demonstrated to allow debondings of piezoelectric patches and the debonding detection.The authors are grateful to the support of the Australian Research Council via a Discovery Projects grant (grant No: DP0346419).