Fiber Damage Prediction of Laminated Composite Plates under Impact

loading using ANSYS

V. Balasubramani

Assistant Professor, Department of Mechanical Engineering, Thiagarajar college of

Engineering, Madurai-625015, Tamil Nadu, India

S. Rajendra Boopathy
Professor, Department of Mechanical Engineering, Anna University, Chennai
-600025, Tamil Nadu, India.

M. Venkatesh
Graduate Student Department of Mechanical Engineering Thiagarajar College of
Engineering, Madurai-625015, Tamil Nadu, India.
and

K. Kalaikovan
Graduate Student, Department of Mechanical Engineering, Thiagarajar College of
Engineering, Madurai-625015, Tamil Nadu, India.

ABSTRACT

Laminated Composite Materials have exceptional mechanical properties that can be tailored

to meet the requirements of a particular application. A serious threat to laminated composite

materials in all applications is liable to impact damage during service. Low velocity impact

damage is often internal and invisible, but can significantly reduce the stiffness and strength.

Hence, it is necessary to study the damage area of glass fiber reinforced laminated composite

plates after impact loading. In this work, glass/epoxy laminated composite plates are

fabricated and mechanical properties are estimated as per ASTM standards. Impact analysis

is performed in ANSYS for various test conditions. The damage area of the laminates after

impact is estimated for fiber failure in tension and compression mode. (±45)2S plates have

high impact strength in fiber tension mode and (30/60) 2S plates have high impact strength in

fiber compression mode.

Keywords: Laminate, Impact, Fiber failure, ANSYS

Biographical notes:

1
V. Balasubramani is working as Assistant professor in Mechanical Engineering Department

at Thiagarajar College of Engineering, Madurai, India. He is now doing research in impact

analysis of GFRP laminated composite materials.

S. Rajendra Boopathy has received his PhD from College of Engineering Guindy, Anna

University Chennai India. He has wide range of experience and interest in impact analysis of

GFRP composite materials, CFRP composite materials and Metal Matrix composite

materials. He is now Professor in Mechanical Engineering department at Anna University,

Chennai.

Venkatesh. M and Kalaikovan. K are Under Graduate students in the Department of

Mechanical Engineering in Thiagarajar college of Engineering, Madurai-625 015 and their

project work is Impact analysis in Composite Materials.

1. Introduction
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Fiber reinforced composite laminates are widely used in many engineering fields, owing to

their high strength-to-weight and stiffness-to-weight ratios. These laminates are fabricated

with tailoring properties in a required direction and have been increasingly used in load-

bearing structures such as aircraft industry, automobile industry, ships, pipe lines, storage

tanks etc. However, they are susceptible to damage due to low velocity impact loading during

its manufacturing and in service. Low velocity impact loading can cause extensive sub-

surface damage and that may not be visible on the laminate surface but can lead to a

significant reduction in the strength of composite laminates. Therefore, considerable

researches have been done to better for better understanding of the impact properties and

residual strength after impact. Due to different material specifications, the impact behavior of

laminated composite structures differs inherently. The damage is hidden inside the composite

structure especially when subjected to low velocity impact. Low velocity impact can produce

internal defects in the form of delamination, matrix failure and fiber breakage. It also reduces

the residual strength and stiffness of the structure.

The resistance to impact depends on several factors of the laminate, such as the material

system, interlaminar strengths, stacking sequence, velocity and mass of impactor and size of

the impacting object. Fiber breakage, delamination, matrix cracking and plastic deformations

are some effects which should be considered when a structure made from composite material

is impacted by a foreign body (Richardson et al 1996, Cantwell et al 1991).

Scarponi evaluated tensile strength reduction of angle ply composite laminates due to low

velocity impact. A correlation between delamination areas and impact energy has been

determined (Scarponi et al 1999). Chotard conducted the low velocity impact damage of

pultruded glass/fiber polyester structures and the observations are influenced by the profile

geometry, impactor mass and impactor size (Chotard 2000).

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Sutherland et al investigated the effects of specimen thickness, impactor kinetic energy and

velocity of impact in laminates. The damaged area was observed for all impact energies

(Sutherland 1999). Found and Howard concluded that the impact force rather than the impact

energy governs the initiation of failure for single impact (Found et al 1995). Ramin

Hosseinzadeh et al estimated that the damaged area of four different types of fiber-

reinforced plates are studied for impact loading and the hybrid composite is suggested for its

well behaviour comparatively the remaining three composite plates (Ramin Hosseinzadeh et

al 2006).

It is evident from the above literature review that an important requirement of laminated

composite materials must have a good response to impact loading. These studies

concentrated on impact damage area of plates with various testing conditions. In the present

study, it is aimed to predict the damage areas in fiber for impacted plates. The values are

predicted in ANSYS using a separate macro program.

2. Laminated Composite Materials

A laminate is a flat arrangement of fibers suspended in a matrix material and is generally

assumed to be orthotropic. Its thickness depends on the material from which it is made. A

laminate is a stack of lamina, as illustrated in Figure 1, oriented in a specific manner to

achieve a desired result. Individual laminas are bonded together by a curing procedure that

depends on the material system used. The mechanical response of a laminate is different

from that of the individual lamina that forms it. The laminate's response depends on the

properties of each lamina, as well as the order in which the lamina is stacked.

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 Figure.1 Laminated composite material with 3 layers

In this work, three different types of laminated composite plates are selected. The

configurations of the plates are given in table 1. The reinforcement used in the test specimens

is unidirectional glass fibers. The matrix selected for the fabrication is epoxy resin. The

fabricated laminated composite material is cut by diamond saw tooth cutter for obtaining

different dimensions to perform different tests.

Table 1. Composite Plate configurations

Layer configuration Thickness(mm) Density(kg/m3)

[0/90]2s 2 1700
[±45]2s 2 1700
[30/60]2s 2 1700

3. Mechanical Properties

For determination of mechanical properties, glass/epoxy laminated composite specimens are

prepared as per ASTM standards and the values are tabulated in Table 2. (Godwin 2000 ,

Mattthews 2000, ASM hand book 2001 ). Then, the specimens are tested under static loading

conditions in LR-30K Universal Testing machine upto the failure point. The coordinate

system used to describe the properties is shown in Figure 2.

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 Figure 2. Coordinate system of laminated composite plates

Table 2. Mechanical Properties of Glass/epoxy laminates

Properties Symbol and unit (0/90)2S (30/60)2S (±45)2S

Longitudinal Young’s EX GPa 24.39 11.438 17.16

Modulus
Transverse young’s EY GPa 24.31 4.35 16.93
Modulus
Shear Modulus GXY GPa 2.605 1.22 1.84

Poisson’s ratio γ12 0.28 0.18 0.24

4. Low Velocity Impact Test

Cantwell and Morton classified velocity upto 10 m/s as low velocity considering test

techniques Charphy, Izod and Drop tower testing. Liu and Malvern suggested that the type of

impact can be classified according to the damage incurred in the laminates (Cantwell et al

1991). Albrate defined that low velocity impact has stress waves through-thickness which

plays no significant in the stress configuration (Albrate, S.1991). In many practical

situations, a low velocity impact does not result in the puncture of the material but it results

in loss of laminate strength.

When laminated composite plates subjected to impact loading, the energy is absorbed by the

composites through elastic deformation. When the energy exceeds certain level, it creates

new surfaces through various failure modes, the failure mechanisms include fiber failure,

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matrix cracking, delamination, and ply splitting. These failures considerably reduce the

mechanical properties of the laminates. The primary concern of this work is to predict the

fiber failure of the composites (Cantwell et al 1991). The test conditions adopted for analysis

are two masses and heights. The values of the mass are 2.305 and 3.935 kg . The values of

heights are 1 and 1.5m.

5. Damage Prediction

Laminated Composite materials display a wide variety of failure mechanisms due to their

complex structure which includes fiber failure, matrix failure and delamination of adjacent

plies. Based on these failure mechanisms, it can be more appropriate to consider the

composite as a structure rather than a material.

Composites are generally strong and have a reasonable impact resistance, if the applied stress

is in the fiber direction. In a well designed laminate, fiber failure marks ultimate failure. It

can be stated that the fiber failure is the only desirable fracture mechanism, since the fiber

network forms the main load carrying structure. The high stiffness of the fibers results in

high stresses in fiber direction. Hence, the stresses acting on the fibers transverse to their

direction cannot be higher than the stresses bearable by the surrounding matrix and the

fiber/matrix interface respectively. These stresses are smaller than the stresses acting parallel

to the fibers.

As a result of anisotropic nature in composite materials, shear stresses have to influence on

the tensile fiber failure. Fiber breakage is the simultaneous fracture of several bundles of

fibers. Obviously, the fractures of thousands of filaments are recorded in total as fiber

breakage. When a fiber breakage occurs, the high-energy will be released in the failing

fibers. It causes locally a total destruction of the fiber/matrix-composite by splitting the fiber

bundles which also prevents the layer from taking loads transverse to the fibers. Moreover,

Fiber breakage usually leads to delamination of adjacent layers (Reid et al 2000).

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6. Fiber Failure

6.1 Fiber Failure in Tension

In composite laminates, fiber failure in tension occurs due to the accumulation of individual

fiber failures within plies. It becomes more critical when there are no enough remaining

unbroken fibers to carry the loads. Hashin criterion is utilized to predict the fiber failure

intension in the laminated composite materials. (Equation 1)

(1)

where Xt is longitudinal tensile strength and S12 is shear strength of the laminates. σ1 is

normal stress along 11 direction, τ12 and τ13 are shear stress along 1-2 and 1-3 directions

respectively for plates after impact (A.C. Orifici et al 2008).

6.2 Fiber Failure in Compression

Fiber failure in compression occurs due to micro buckling and the formation of bends. Micro

buckling is a more global failure mode while kinking seems to be initiated by local micro

structural defects and is the most common failure feature. To predict the fiber failure in

compression in the laminated composite materials, Hashin criterion is identified in Equation

where Xc is longitudinal compressive strength of the laminates. σ1 is normal stress along 11

direction for plates after impact (A.C. Orifici et al 2008).

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7. Simulation

ANSYS is an engineering simulation software based on the Finite element method and it is

capable of performing stress analysis, thermal analysis, modal analysis, frequency response

analysis, transient simulation and also coupled field analysis. ANSYS Parametric Design

Language module is selected for this analysis. It allows users to execute all the commands

required to pre process, solve and post process the problem, from a separate text file known

as macro.

In ANSYS, the composite plates are modeled with SHELL 163 element, and impactor is

modeled with SOLID 164 elements (Figure 3). The dynamic analysis is performed on the

plate and the impactor. The steps used in the analysis are summarized below

 At the maximum displacement time step, the stresses in the global co-ordinates for

each node are calculated (Figure 8).

 The stresses are transformed to the material axes.

 A failure index is calculated at each node using a Hashin failure criterion with the

help of the separate macro program.

 When failure index exceeds 1, the damage nodes are predicted and plotted in

ANSYS.

 The damage nodes are not predicted when the failure index does not exceed 1.

 The damaged nodes mapped as an area and its values are calculated (Figure 7).

9
 Figure3.Laminated composite plates with Impactor modeling in ANSYS

8. Results and Discussions

The test results of three types of laminated composite plates with damage area in fiber failure

both tension and compression are tabulated in Table 3.

The damage area in fiber tension is greater than that of damage area in fiber compression

mode in three plates for all test conditions because, shear stress along 1-2 and 1-3 directions

are influenced in fiber tension mode. Damage area in (±45) 2S plates are less than (0/90) 2S and

(30/60)2S plates in fiber tension mode. Shear stresses are introduced normally in + 45and – 45

directions and induced shear stresses are compensated (±45) 2S plates of plates. So (±45)2S

plates have higher impact strength than other two plates. (Figure 4,6,10).

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 Table 3. Damage area for three types of plates

Orientation Mass Height Damage area (mm2)

Fiber tension Fiber Compression
(kg) (m)
2.305 1 866 Nil
1.5 4153 1961
[0/90]2s 3.935 1 4608 4608
1.5 8730 4608

2.305 1 2500 Nil

1.5 3803 2500
[±45]2s 3.935 1 4608 4608
1.5 7890 7043
[30/60]2s 2.305 1 4995 Nil
1.5 7780 Nil
3.935 1 10370 Nil
1.5 13550 Nil

For (30/60)2S plates, no failed nodes are predicted in ANSYS for all test conditions in fiber

compression mode. But (30/60)2S plates predict more failure area in fiber tension mode. For

(0/90)2S and (± 45) 2S plates, no failure area is plotted in ANSYS for 1m height in two masses

in compression mode and (± 45) 2S plates show more damage area than other two plates in

fiber compression mode. (Figure 5)

The (0/90)2S plates predicted minimum damage area in fiber tension mode (Figure 9) whereas

it show higher damage area in fiber compression mode. The variation of damage area for

three types of laminate plates in fiber tension mode and compression mode are shown in

Figure 11 and 12.

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 Figure 4. Predicted failed nodes in[0/90]2s plates in fiber failure tension with 3.935kg - 1.5m

height

Figure 5. Failure area in [±45]2s plates fiber failure compression mode with 3.935kg - 1m

height

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Figure 6. Failure area in [30/60]2s plates in fiber failure tension mode with 2.305 g - 1m

height

Figure 7. Mapped area in (±45)2S plates fiber failure tension mode with 3.935 kg -1 m
height

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Figure 8. Stress distribution along y-direction for (0/90)2S plates with 2.305 kg -1 m height

Figure 9. Predicted failed nodes in (0/90) 2S plates in fiber failure - tension mode with 2.305
kg -1 m height

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Figure 10. Predicted failed nodes in (±45)2S plates in fiber failure - tension mode with 2.305
kg -1 m height

16000
14000
Damage area in mm 2

12000
10000
8000
6000
4000
2000
0
[0/90]2s [“ 45]2s [30/60]2s
Orientation
2.305 kg 1m 2.305 kg 1.5m
3.935kg 1m 3.935kg 1.5m

Figure 11.Variation of damage area in glass/epoxy laminated plates - Fiber failure in tension

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 Figure 12.Variation of damage area in glass/epoxy laminated plates - Fiber failure in

compression

9. Conclusions

Three types of glass/ epoxy laminated composite plates are fabricated and the mechanical

properties are estimated as per various ASTM standards. The impact analysis is performed in

ANSYS for various test conditions. Fiber damage area in tension and compression mode is

predicted in ANSYS for all test conditions. The following conclusions are drawn:

 The (±45)2S plates have shown good results comparing to (0/90)2S and (30/60)2S

plates in fiber tension mode whereas (±45) 2S plates displayed higher damage area in

fiber compression mode.

 There is no damage area predicted for (30/60) 2S plates whereas (0/90) 2S and (±45)2S

plates displayed damage area in fiber compression mode.

 The (30/60)2S plates have high impact strength in fiber compression mode.

 The (±45)2S plates have high impact strength in fiber tension mode.

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10. References.

Albrate, S.(1991). ‘Impact on laminated composite materials’, Applied Mechanics Review,

Vol.44, No.4, pp155-190.

ASM- Hand book Volume 21-Composites, ASM International.

Cantwell, W.J. and Morton, J. (1991), “The impact resistance of composite materials- a
review”. Composites, Vol. 22, No.5, pp.347-362.

Chotard T.J, Pasquiet. J, and Benzeggagh M.L. (2000) “Impact response residual
performances of GRP Pultured shapes under static and fatigue loading”, Composites Science
and Technology, Vol.60. No 6, 2000,pp 895-912.

Found, M.S. and Howard, I.C. (1995), “ Single and multiple impact behaviour of a CFRP
laminate” Composite structures, Vol.32, pp159-163.

Godwin, E.W. (2000). Mechanical testing of advanced fibers, CRC- Woodhead Publishing
Ltd., London. pp 48-49.

Liu, D. and Malvem, L.E. (1987), “Matrix cracking in impacted glass/ epoxy plates”,
Journal of Composite Materials, Vol.21, pp 594-609.

Mattthews, F.L. (2000). Mechanical testing of advanced fibers, CRC- Woodhead Publishing
Ltd., London. pp91.

Orifici, A.C, Herzberg, I, and Thomson, R. S, (2008), “Review methodology for composite
material incorporating failure” Composites and Structures, Vol.86., pp 194-210.

Ramin Hosseinzadeh, Mahmood Mehrdad Shokrieh, and Larry Lessard,( 2006), “Damage
behavior of fiber reinforced composite plates subjected to drop weight impacts”, Composites
Science and Technology, Vol.66, pp.61–68.

Reid, S. R. and Zhou, G. (2000). Impact behaviour of fiber-reinforced composite materials

and structures, Woodhead Publishing ltd, Cambridge England. pp 10-27

Richardson, M.O.W.and Wisheart, M.J. (1996), “Review of low-velocity impact properties

of composite materials” Composites Part A, 27A, pp.1123-1131.

Scarponi, C. Briotti, G. Barhoni,, R. and Macrone, A. (1999) “ Reduction of tensile strength

in angle –ply composite laminates due to low-velocity impact”, Journal of Reinforced
Plastics and Composites, Vol.19, No 4,1999, pp322-399.

Sutherland, L. S, Soares, C. and Guedes, (1999), “Impact tests on woven roving E-

glass/polyester laminates” Composites Science and Technology, Vol.59. No 10, pp 1553-
1567.

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