CRASH SIMULATION OF FIBRE METAL LAMINATE FUSELAGE A THESIS SUBMITTED TO THE UNIVERSITY OF MANCHESTER FOR THE DEGREE OF DOCTOR OF PHILOSOPHY (PhD) IN THE FACULTY OF ENGINEERING AND PHYSICAL SCIENCES 2014 AHMAD SUFIAN ABDULLAH SCHOOL OF MECHANICAL, AEROSPACE AND CIVIL ENGINEERING Table of Contents Contents 2 List of Figures 6 List of Tables 9 Abstract 10 Declaration 11 Copyright Statements 12 Acknowledgement 13 Chapter 1 INTRODUCTION ................................................................................................. 14 1.1. Background and Motivation ............................................................................... 14 1.2. Aim of Research ................................................................................................. 16 1.3. Outline of Structure ........................................................................................... 16 Chapter 2 LITERATURE REVIEW ......................................................................................... 18 2.1 Crash Simulation of Aircraft ............................................................................... 18 2.1.1 Introduction of Aircraft Crash Simulation ................................................... 18 2.1.2 Methodology of Aircraft Crash simulation .................................................. 18 2.1.3 Crash Simulation of Composite Aircraft Fuselage ........................................ 21 2.2 Failure and Impact Response of Fibre Metal Laminate and its Constituents ...... 24 2.2.1 Introduction to Failure and Impact Response of Fibre Metal Laminate ....... 24 2.2.2 General Review on Mechanical Properties of Fibre Metal Laminate ........... 24 2.2.3 Bending and Buckling Behaviour of Fibre Metal Laminate .......................... 26 2.2.4 Impact Response and Damage of Fibre Metal Laminate under Low Velocity Impact …………………………………………………………………………………………………………………..27 2.2.5 Review on Failure and Impact Response of Fibre Reinforced Composite Laminate under Low Velocity Impact ......................................................................... 30 2.2.6 Review on Failure and Impact Response of Metal under Low Velocity Impact …………………………………………………………………………………………………………………..34 2.2.7 Finite Element Modelling of Impact and Damage on Fibre Metal Laminate and Its Constituents................................................................................................... 35 2.3 Summary of the Literature Review ..................................................................... 38 Chapter 3 BACKGROUND THEORY OF FIBRE METAL LAMINATE ......................................... 39 3.1 Introduction on Fibre Metal Laminate ................................................................ 39 3.1.1 GLARE: A Glass Fibre Reinforced Based Fibre Metal Laminate .................... 39 3.1.2 Impact Behaviour of GLARE ........................................................................ 40 3.2 Aluminium Alloys ............................................................................................... 42 3.2.1 Stress-strain Relationship of Isotropic and Homogeneous Materials ........... 42 3.2.2 Impact Behaviour of Aluminium Alloys Structure ........................................ 45 3.3 Fibre Reinforced Composite Laminate................................................................ 48 3.3.1 Stress-strain Relationships of Fibre Reinforced Composite Laminate .......... 48 3.3.2 Analysis of a Composite Lamina ................................................................. 49 3.3.3 Failure of Fibre-reinforced Composite Laminate ......................................... 52 3.3.4 Impact Behaviour of Fibre-Reinforced Composite Laminate under Low Velocity Impact ......................................................................................................... 56 Chapter 4 FINITE ELEMENT METHOD................................................................................. 59 4.1. Introduction....................................................................................................... 59 4.1.1. Introduction of Finite Element Method in Aircraft Crash Analysis ............... 59 4.1.2. General Description of Finite Element Method ........................................... 60 4.1.3. Abaqus Finite Element (FE) Software .......................................................... 61 4.2. Nonlinear Dynamic Analysis ............................................................................... 62 4.2.1. Nonlinear Analysis of Aircraft Structure ...................................................... 62 4.2.2. Dynamic Analysis of Aircraft Structure........................................................ 64 4.3. Selection of Elements for Discretisation ............................................................. 66 4.3.1. Shell element ............................................................................................. 66 4.3.2. Incompatible Mode Solid Element .............................................................. 69 4.3.3. Reduced Integration Element ..................................................................... 69 4.3.4. Hourglass Control ....................................................................................... 70 4.3.5. Cohesive Element ....................................................................................... 71 4.4. Material and Damage Model of Aluminium Alloy ............................................... 76 4.4.1. Material Model of Aluminium Alloy ............................................................ 76 4.4.2. Damage model of Aluminium Alloy ............................................................ 77 4.4.3. Onset of damage in Aluminium Alloy .......................................................... 77 4.4.4. Damage Evolution of Aluminium Alloy........................................................ 77 4.5. Material and Damage Model of Fibre-Reinforced Composite Laminate .............. 79 3 4.5.1. Material Model of Fibre-Reinforced Composite Laminate ........................... 79 4.5.2. Onset of damage in Fibre-Reinforce Composite Lamina .............................. 80 4.5.3. Damage Evolution of Fibre-Reinforced Composite Lamina .......................... 82 4.6. Interaction and Contact Modelling ..................................................................... 85 4.7. Constraint and Connection Modelling ................................................................ 88 4.7.1. Mesh Tie Constraints .................................................................................. 88 4.7.2. Mesh Independent Fasteners ..................................................................... 88 4.8. Computational Facilities in The University of Manchester .................................. 89 Chapter 5 DEVELOPMENT OF FIBRE METAL LAMINATE FUSELAGE CRASH MODEL ............. 90 5.1. Introduction of Aircraft Crash Methodology ....................................................... 90 5.2. Methodology of Crash Modelling of Fibre Metal Laminate Fuselage................... 91 5.3. Validation of Material and Damage Model Subjected to Impact Loading ............ 93 5.3.1. Validation of Aluminium Alloy Material and Damage Model ....................... 93 5.3.2. Validation of Composite Laminate Material and Damage Model .............. 102 5.4. Validation of General Impact Modelling ........................................................... 112 5.5. Verification of Fuselage Frame Impact Modelling ............................................. 119 5.5.1. Finite Element Modelling of Fuselage Frame ............................................ 119 5.5.2. Verification Results of Fuselage Frame Impact Model ............................... 122 5.6. Development of Crash Impact FE Model of Aluminium Alloy Fuselage Section . 126 5.6.1. Geometric Information and Assumptions ................................................. 126 5.6.2. Discretisation of the Fuselage Section ...................................................... 127 5.6.3. Material Assignment ................................................................................ 127 5.6.4. Impact and Contact Modelling ................................................................. 127 5.6.5. Location of Mass ...................................................................................... 128 5.7. Development of Crash Impact FE Model of GLARE Fuselage Section ................ 129 5.8. Evaluation of Acceleration Response at Floor-Level.......................................... 130 5.8.1. Data collection and processing of the acceleration response during crash event …………………………………………………………………………………………………………………130 5.8.2. Human tolerance towards acceleration .................................................... 130 Chapter 6 RESULTS AND DISCUSSIONS ............................................................................ 133 6.1. Introduction..................................................................................................... 133 6.2. Energy Dissipation during Crash ....................................................................... 133 6.3. Structural Deformation of Fuselage Structure .................................................. 141 6.4. Acceleration at Floor Level ............................................................................... 150 4 Chapter 7 Conclusions and Future Work.......................................................................... 153 7.1. Conclusions.....................................................................................................