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Modeling and Experimental Studies of Crack Propagation in Laminated Glass Sheets
Modeling and Experimental Studies of Crack Propagation in Laminated Glass Sheets
2014-01-0801
Published 04/01/2014
Copyright © 2014 SAE International
doi:10.4271/2014-01-0801
saematman.saejournals.org
ABSTRACT
Polyvinyl Butyral (PVB) laminated glass has been widely used in automotive industry as windshield material. Cracks on
the PVB laminated glass contain large amount of impact information, which can contribute to accident reconstruction
investigation. In this study, the impact-induced in-plane dynamic cracking of the PVB laminated glass is investigated.
Firstly, a drop-weight combined with high-speed photography experiment device is set up to investigate the radial cracks
propagation on the PVB laminated glass sheet. Both the morphology and the velocity time history curve of the radial
cracks are recorded and analyzed to investigate the basic mechanism of the crack propagation process. Afterwards, a
three-dimensional laminated plate finite element (FE) model is set up and dynamic cracking process is simulated based on
the extended finite element method (XFEM). Good agreements between the experimental and numerical results on the
radial crack velocity time history and the crack morphology validate the effectiveness of the FE model. Results may
provide an experimental technique as well as useful finite element model of PVB laminated glass for further systematically
studies to explore the fracture mechanism and safety design improvement of PVB laminated glass.
CITATION: Xu, X., Chen, J., Xu, J., Li, Y. et al., "Modeling and Experimental Studies of Crack Propagation in Laminated Glass
Sheets," SAE Int. J. Mater. Manf. 7(2):2014, doi:10.4271/2014-01-0801.
motivation for this research. In this study, the radial crack parallel light by the objective lens and gathered in the
propagation process of the PVB laminated glass plate is corresponding array film camera by the eyepiece lens after
obtained by high-speed photography system to analyze its projecting through the specimen. The final test images are
fracture mechanism. Afterwards, laminated glass plate finite recorded on the film in the dark box. The delay controller is
element (FE) model is built using a layered structure. Finally, used to receive the impact signal and control the ignition time
the FE model is validated by the comparison of simulation of each spark plug. The time interval of the delay controller can
results and experimental results. be set between 1 microsecond and 999 microseconds to meet
the test requirements. An electric-light receiver is placed in
front of the array spark plug in order to record the real ignition
EXPERIMENT DETAILS time of the spark plug and verify whether the system is working
properly. An oscilloscope is used to receive the voltage signal
Experimental Specimen from the electric-light receiver transferred by the optical signal.
The PVB laminated glass specimen used in the experiment is Finally, ignition time is judged by observing the recorded
a rectangular plate with the dimension of 200mm×150mm signals on the oscilloscope.
shown in Figure 1. The PVB interlayer is 0.76 mm thick
sandwiched by two sheets of 2 mm-thick soda-lime glass. The At the beginning of the experiment, the drop-weight is moved
specimen adopts the same processing method as the to a specific height and released to generate different impact
automotive laminated windshield under compression at 10 bar energy. The vertical impact is transferred into horizontal impact
and 120 °C[5]. The laminated glass specimen is fixed by two through impact connecting rod and impact direction convertor,
steel frames, with a rubber interlayer between the specimen finally applied to the center part of the specimen. The circuit of
and the frame in order to avoid the damage of the specimen delay controller is connected and sends a trigger signal to the
and eliminate the residual stress. The tightening torque of the delay controller when the drop-weight impacts the connecting
bolts is set to to 4 N · m simulate the clamped boundary rod. Then the delay controller output the signal to the multi-
conditions of the automotive windshield. The vertical impact spark system. The 16 spark plugs ignite according to the
load is applied in the center of the specimen by the impact predetermined time interval sequentially, while the optical
direction convertor (shown in Figure 1) which convert the recording system will record the corresponding 16 images.
vertical load into horizontal load under the impact of a free-
falling drop-weight with mass of 2 kg at the initial height of 700
mm (i.e. with the impact velocity of 3.7 m/s). The impact Verification of Experimental Device
direction convertor is made of 45 steel. The end part of the A series of pre-experiments are conducted to verify the
impact direction convertor is equipped with an impact head experimental system via efficiency calibration. Here, we apply
which can be designed into different shapes. In this study, we the impact efficiency (η) to calibrate the experimental system,
use the hemispherical shape of the impact head. which is described as:
(1)
MODEL AND METHOD where K represents the bulk modulus of PVB[1]. The maximum
allowable principal stress σglass of different soda-lime glass are
Model Setup different due to its intrinsic stochastic flaws, usually from 10
A cylinder with hemispherical head is used to model the MPa to 60 MPa, and the simulation with σglass of 60 MPa fit well
impactor. The impactor has a mass of 2 kg by applying an with the experimental results. Other material and impact
equivalent density in order to simplify the complex structure of parameters are shown in Table A2.
the impactor. The three-dimensional laminated plate FE model
is developed with solid elements according to the specimen of Fundamentals of XFEM
PVB laminated glass. The layered structured of the laminated
The extended finite element method extends the classical finite
sheet is modeled using 15 layers of three-dimensional eight-
element method by enriching the solution space with
node reduced integration solid (C3D8R) elements with shared
discontinuous functions. The element mesh in XFEM is
nodes at their boundaries: the outside 6 C3D8R elements
generated regardless of the existence and location of the
representing the glass layer and the inside 3 C3D8R elements
cracks.
standing for the PVB layer shown in Figure 2. The C3D8R can
solve the displacement accurately, and the accuracy of
The discontinuous displacement field across the crack facing
analysis will not be affected when the distortion of the grid
away from the crack tip can be expressed in the form
exists, so C3D8R is suitable in this simulation. Each material
below[16]:
needs at least three elements in the longitudinal direction with
more than two integration points to ensure the accuracy of the
results in order to analyze the longitudinal situation. The glass
plate FE model is meshed using 1mm×1mm surface size
element with a mesh convergence study and consists of (4)
112500 elements in total.
where n is the total number of nodes in the mesh, Ni(x) is the
shape function associated with node i, ui are the classical
DOFs of node I, bi and cil are the DOFs associated with H(x),
and H(x) is the Heaviside enrichment function. The crack tip
function is given below[16]:
Figure 2. The structure of the laminated plate FE model.
(2)
The power law model is used to compute the equivalent circle with radius r at the moment of t as shown in Figure 3 (c).
fracture energy release rate GequivC. The power law model is Therefore, the propagation velocity of radial cracks can be
described below[21]: described below:
(8)
(7)
where GIC, GIIC, GIIIC represent the mode I, mode II and mode
III critical energy release rate, am, an, ao are exponents.
Model Verification
Simulations are conducted using the commercial finite element
code ABAQUS IMPLICIT in order to verify the laminated glass
plate model compared with the dynamic experiment results of
PVB laminated glass under drop-weight. Figure 3. The propagation process of radial cracks under the impact
height of 700 mm, impact weight of 2 kg.
Here, we adopt both quantitative and qualitative method to
compare numerical simulation and dynamic experiment.
Qualitative validation is to compare crack propagation patterns
of simulation and experiment with the velocity of 3.7 m/s at the
vertical impact. Quantitative validation is to compare the radial
crack velocity-time curve of simulation and experiment with the
velocity of 3.7 m/s at the vertical impact.
cracks on the loaded-side, and the radial cracks propagate stages, i.e. rising stage, stable stage, descending stage. In the
earlier than the circular cracks, which is consistent with our first stage, the crack velocity rises sharply from zero, and the
previous study[14]. energy release rapidly until it reaches its peak. Then the crack
velocity increases to the peak value and remain stable in the
vicinity of the peak value for a short period in the second stage.
Qualitative Model Verification (Crack Finally, the crack velocity shows a downward trend due to the
Morphology) effect of the boundaries. Figure A3 shows that the slope of the
Figure 5 shows the radial crack morphology of the simulation simulation is greater than the experiment in the rising stage
results compared with the experimental results under the and smaller in the descending stage. Reasons can be
impact velocity of 3.7 m/s. As can be seen from the summarized as follows: (1) the impact speed may not reach
experimental image shown Figure 5 (b), a total of 22 radial 3.7 m/s for the energy transfer efficiency is not 100%
cracks exist in this picture and most of them have propagated (explanation of the rising stage); (2) the rebound speed of the
to the border of the specimen. Figure 5 (a) shows the radial simulation is higher than the experiment (explanation of the
crack morphology and its hoop stress field of the simulation descending stage). As can be seen, the peak values as well as
results and 20 radial cracks in all propagating close to the the entire time course of the simulation fit well with the
border present in the plate. From the perspective of radial corresponding impact test results.
crack morphology, i.e. number of cracks and crack length, the
simulation results are in good agreement with the experimental In summary, both the crack morphology (i.e. length and
results. number of the cracks) and the crack velocity time history curve
of the simulation results are in good agreement with the
experimental results. So a robust FE model system of fairly
high quality has been built.
CONCLUSIONS
In this paper, the radial crack propagation process is obtained
by high-speed photography experiment, and found the
propagation sequence of the three types of cracks. The basic
rules of the radial crack propagation process have been found
through the calculated crack velocity-time curve. Laminated
(a). Simulation image (unit: Pa) glass plate with layered structure is setup. The crack
propagation patterns and the crack velocity-time curve of
simulation results fit well with the corresponding test results
under the impact velocity of 3.7 m/s when we verify the
specimen FE model. This study lays a solid step for systematic
numerical studies on fracture propagation mechanism and
energy absorption characteristics of the PVB laminated glass
in the future.
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CONTACT INFORMATION
Mr. Xiaoqing Xu
xuxq12@mails.tsinghua.edu.cn
State Key Laboratory of Automotive Safety & Energy,
Department of Automotive Engineering
Tsinghua University, Beijing, China, 100084
Tel: 86-10-62786835
Fax: 86-10-62772721
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APPENDIX
APPENDIX A: FIGURES AND TABLES
Figure A3. Comparison of the radial crack propagation velocity between the experimental results and the simulation results under the impact height of
700 mm, impact weight of 2 kg.
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