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来模拟航空航天应用中使用的复合材料结构的渐进失效。 复合材料的失效建模是一个高度复杂的多尺度问题，分析的结果意味着保真度和速度之间的交易取决于损伤模拟的规模和结构的大小。 所提出的技术提供了一个通用的框架，使用一个共同的实验材料表征计划来分析组合的铺叠和加载方案。 该技术结合了制造对结构性能的影响。通过先进的模拟工具，复合材料结构的设计可以更有信心和安全性，以及在一个更短的时间框架相比，目前的程序。可靠和快速的预测工具的可用性可以使和加速轻质复合材料的使用，这反过来又可以导致商业和军用飞机的更好的燃油效率。这个I-Corps项目是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水平上可观察到的主要损伤模式，例如分层，宏观基体开裂，分裂。这种分析水平是结构认证过程中最耗时和昂贵的。所提出的技术可用于加速认证过程，而不影响准确性，通过识别一组基本模型特征，从基本的试样测试，必须纳入预测复合材料结构的渐进式故障在广泛的铺层和加载情况。在对所提出的技术的测试中，盲预测中实验数据的5%以内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的影响，这会影响复合材料中的残余应力和变形。这些因素影响机械性能，如刚度和强度。该奖项反映了NSF的法定使命，并通过使用基金会的知识价值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.