Identification of process-induced residual stress/strain distribution in thick thermoplastic composites based on in situ strain monitoring using optical fiber sensors

2019 ◽  
Vol 53 (24) ◽  
pp. 3445-3458 ◽  
Author(s):  
Takuhei Tsukada ◽  
Shu Minakuchi ◽  
Nobuo Takeda
Keyword(s):  
Residual Stress ◽  
Strain Distribution ◽  
Bending Strength ◽  
Thermoplastic Composite ◽  
High Rate ◽  
Strength Increase ◽  
Transverse Strain ◽  
Thickness Direction ◽  
Stress Strain ◽  
Thin Carbon

In thick thermoplastic composite laminates, nonuniform temperature distribution arises in the through-thickness direction during high-rate manufacturing processes. This causes the so-called thermal skin-core effect. The surface region solidified in advance constrains shrinking of the inside region, so nonuniform residual stress/strain distribution arises in the through-thickness direction. This study quantitatively clarified this mechanism and identified the amount of residual stress/strain by utilizing fiber optic–based internal strain measurement and process simulation. First, in-plane transverse strain of thin carbon fiber/polyphenylenesulfide laminates was measured using fiber Bragg grating sensors to determine two key parameters for stress/strain simulation; thermal/crystalline shrinkage strain and composite stiffness. Abaqus-based simulation using these properties was then performed to calculate stress/strain distribution in thick laminates. The simulated strain agreed well with the measured value and it was confirmed that the residual stress developed in a relatively low temperature range. In addition, transverse three-point bending tests were conducted to validate the amount of residual stress calculated by the simulation. The bending strength increased by the thermal skin-core effect and the amount of strength increase coincided with the simulation, confirming the validity of the simulation. Extension of the proposed approach to the evaluation of the morphological skin-core effect is also discussed.

Assessing residual stress redistribution during annealing in thick thermoplastic composites using optical fiber sensors

2018 ◽  
Vol 33 (1) ◽  
pp. 53-68 ◽  
Author(s):  
Takuhei Tsukada ◽  
Shu Minakuchi ◽  
Nobuo Takeda
Keyword(s):  
Residual Stress ◽  
Optical Fiber ◽  
Strain Distribution ◽  
Optical Fiber Sensors ◽  
Thermoplastic Composite ◽  
Bending Test ◽  
Degree Of Crystallinity ◽  
Thickness Direction ◽  
Fiber Sensors ◽  
Thick Laminates

In thick thermoplastic composite laminates, nonuniform temperature and cooling rate distribution arises in the through-thickness direction during cost-effective high-rate manufacturing processes. Annealing is often carried out after molding to homogenize degree of crystallinity (DOC) and to reduce residual stress. Even though the change in the residual stress/strain distribution occurring inside thick laminates by this heat treatment is practically important, the changing process and the detailed mechanism are not sufficiently clarified. This present study addresses development and redistribution behavior of residual stress through both molding and annealing using multiple optical fiber sensors deployed in the thickness direction. This article begins by explaining about process monitoring of thick laminates to discuss process-induced strain distribution depending on cooling conditions during molding. Next, strain monitoring is performed during annealing, and the strain change caused by cold crystallization is clarified. Finally, the residual stress distribution is evaluated by a transverse three-point bending test, and the validity of the redistribution mechanism deduced from the strain measurement is confirmed.

scholarly journals Residual stress-strain relationship for the biochar-based mortar after exposure to elevated temperature

2021 ◽  
pp. e00540
Author(s):  
Satheeskumar Navaratnam ◽  
Hendrik Wijaya ◽  
Pathmanathan Rajeev ◽  
Priyan Mendis ◽  
Kate Nguyen
Keyword(s):  
Residual Stress ◽  
Elevated Temperature ◽  
Stress Strain ◽  
Strain Relationship

Effect of Residual Stress or Plastic Deformation History on Fatigue Life Simulation of Pipeline Dents

2018 ◽  
Author(s):  
Xian-Kui Zhu ◽  
Rick Wang
Keyword(s):  
Residual Stress ◽  
Plastic Deformation ◽  
Fatigue Life ◽  
Residual Stresses ◽  
Three Dimensional ◽  
Strain History ◽  
Deformation History ◽  
Stress Strain ◽  
Element Analysis ◽  
Fea Model

Mechanical dents often occur in transmission pipelines, and are recognized as one of major threats to pipeline integrity because of the potential fatigue failure due to cyclic pressures. With matured in-line-inspection (ILI) technology, mechanical dents can be identified from the ILI runs. Based on ILI measured dent profiles, finite element analysis (FEA) is commonly used to simulate stresses and strains in a dent, and to predict fatigue life of the dented pipeline. However, the dent profile defined by ILI data is a purely geometric shape without residual stresses nor plastic deformation history, and is different from its actual dent that contains residual stresses/strains due to dent creation and re-rounding. As a result, the FEA results of an ILI dent may not represent those of the actual dent, and may lead to inaccurate or incorrect results. To investigate the effect of residual stress or plastic deformation history on mechanics responses and fatigue life of an actual dent, three dent models are considered in this paper: (a) a true dent with residual stresses and dent formation history, (b) a purely geometric dent having the true dent profile with all stress/strain history removed from it, and (c) a purely geometric dent having an ILI defined dent profile with all stress/strain history removed from it. Using a three-dimensional FEA model, those three dents are simulated in the elastic-plastic conditions. The FEA results showed that the two geometric dents determine significantly different stresses and strains in comparison to those in the true dent, and overpredict the fatigue life or burst pressure of the true dent. On this basis, suggestions are made on how to use the ILI data to predict the dent fatigue life.

SHOOTING SILK: STRESS STRAIN PROPERTIES OF SINGLE FIBRES AT HIGH RATE

2012 ◽  
Vol 45 ◽  
pp. S86
Author(s):  
Beth Mortimer ◽  
Daniel Drodge ◽  
Clive Siviour ◽  
Chris Holland
Keyword(s):  
High Rate ◽  
Stress Strain ◽  
Single Fibres

Finite element analysis of the residual stress of automotive wheel made of long glass fiber-reinforced thermoplastic composite

2018 ◽  
Vol 233 (10) ◽  
pp. 3592-3602 ◽  
Author(s):  
Weihao Chai ◽  
Xiandong Liu ◽  
Yinchun Shan ◽  
Xiaofei Wan ◽  
Er Jiang
Keyword(s):  
Residual Stress ◽  
Stress Distribution ◽  
Simulation Method ◽  
Residual Stress Distribution ◽  
Thermoplastic Composite ◽  
Element Analysis ◽  
Simulation Accuracy ◽  
Glass Fiber Reinforced ◽  
Long Glass Fiber ◽  
Bending Fatigue Test

To increase the simulation accuracy, a finite element analysis method for the prediction of the residual stress distribution in the injection molded wheel made of the long glass fiber-reinforced thermoplastic composite (LGFT) is studied, and a simulation method of the wheel bending fatigue test considering the residual stress distribution is investigated in this paper. First, the in-cavity residual stress is calculated using the molding simulation method. Then the residual stress relaxation process is analyzed and the final residual stress distribution is obtained. With the residual stress as the initial stress, the structural simulation of the LGFT wheel under the bending load is performed. To evaluate the influence of the residual stress on the LGFT wheel, an additional simulation without considering the residual stress is conducted. The result shows that the interior stress considering residual stress is much higher than that without considering residual stress. To verify the simulation accuracy of these two cases, the high-stress area locations in the simulation results are compared with the damage locations in physical bending fatigue test. The result illustrates that the simulation result considering the residual stress accords with the experimental result better. Therefore, the simulation result of the residual stress is reasonable, and it is necessary to consider residual stress in the simulation of the LGFT wheel.

Routes towards Novel Active Pressure Sensors in SOI Technology

2011 ◽  
Vol 276 ◽  
pp. 145-155
Author(s):  
Benoit Olbrechts ◽  
Bertrand Rue ◽  
Thomas Pardoen ◽  
Denis Flandre ◽  
Jean Pierre Raskin
Keyword(s):  
Finite Elements ◽  
Strain Distribution ◽  
Pressure Sensors ◽  
High Sensitivity ◽  
Stress Strain ◽  
Pressure Transducers ◽  
Active Devices ◽  
Active Pressure ◽  
Soi Technology

In this paper, novel pressure sensors approach is proposed and described. Active devices and oscillating circuits are directly integrated on very thin dielectric membranes as pressure transducers. Involved patterning of the membrane is supposed to cause a drop of mechanical robustness. Finite elements simulations are performed in order to better understand stress/strain distribution and as an attempt to explain the early burst of patterned membranes. Smart circuit designs are reported as solutions with high sensitivity and reduced footprint on membranes.

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