I-Corps: Software tools to model the progressive failure of polymer matrix composite structures

这个i-Corps项目的更广泛的影响/商业潜力是开发软件工具，以模拟航空航天应用中使用的复合材料结构的逐渐失效。复合材料的失效建模是一个高度复杂的多尺度问题，分析结果表明，根据损伤模拟的规模和结构的大小，在保真度和速度之间进行了权衡。所提出的技术提供了一个通用框架，用于使用通用的实验材料表征计划来分析上篮和加载场景的组合。该技术结合了制造对结构性能的影响。通过先进的仿真工具，复合材料结构的设计可以更加自信和安全，而且与目前的程序相比，可以在更短的时间内完成。可靠和快速的预测工具的可用性可能会促进和加速轻质复合材料的使用，这反过来可能会导致更好的商用和军用飞机的燃油效率。这个I-Corps项目基于有限元算法的开发，该算法明确地模拟了在复合材料结构的子部件级别可观察到的主要损伤模式，如分层、宏观基质开裂和分裂。在结构的认证过程中，这个分析级别是最耗时和最昂贵的。建议的技术可用于在不影响准确性的情况下加快认证过程，方法是确定一组基本模型特征，这些特征可以从基本试件试验中表征，必须结合这些特征来预测复合材料结构在广泛的铺层和加载情况下的渐进破坏。在对所提出的技术的测试中，盲预测中5%的实验数据的误差通常比当前方法快一个数量级的计算时间。此外，分析还考虑了固化过程对复合材料残余应力和变形的影响。这些因素会影响机械性能，如刚度和强度。这项提议的技术在同一有限元软件中集成了固化和故障建模。该奖项反映了NSF的法定使命，并通过使用基金会的智力优势和更广泛的影响审查标准进行评估，被认为值得支持。

The broader impact/commercial potential of this I-Corps project is the development of software tools to model the progressive failure of composite structures used in aerospace applications. Failure modeling of composites is a highly complex multiscale problem, and the result of the analysis implies a trade between fidelity and speed depending on the scale at which damage is simulated and the size of the structure. The proposed technology provides a general framework to analyze combinations of layups and loading scenarios using a common experimental material characterization plan. The technology incorporates the effect of manufacturing on the performance of the structure. By advancing simulation tools, composite structures may be designed with more confidence and safety as well as in a much shorter time frame compared to current procedures. The availability of reliable and fast predictive tools may enable and accelerate the use of lightweight composite materials, which in turn may lead to better fuel efficiency of commercial and military aircraft.This I-Corps project is based on the development of a finite element algorithm that models explicitly the dominating damage modes observable at the subcomponent level of a composite structure such as delamination, macroscopic matrix cracking, and splitting. This analysis level is the most time consuming and expensive in the certification process of a structure. The proposed technology may be used to accelerate the certification process without compromising accuracy by identifying a set of fundamental model features, characterizable from basic coupon tests, that must be incorporated to predict the progressive failure of composite structures in a wide range of layups and loading scenarios. In tests of the proposed technology, errors within 5% of experimental data in blind predictions are typically achieved in computational times of one order of magnitude faster than current methods. In addition, the analysis also considers the effects of the curing process, which affects the residual stresses and deformations in the composite. These factors influence mechanical properties such as stiffness and strength. The proposed technology integrates curing and failure modeling within the same finite element software.This award reflects NSF's statutory mission and has been deemed worthy of support through evaluation using the Foundation's intellectual merit and broader impacts review criteria.