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Table 1. Nominal properties of DLR cylinders.
25
Property Nominal Data 20
Total length (mm) 540 15 Perfect
Free length (mm) 500 10 Thickness Impf.
3.1 Geometric Imperfections All variables have their common meanings [10, 11].
An example of an imperfect surface generated using
To accurately model realistic geometric
this approach is shown in Figure 2.
imperfections, ATOS-scanned geometrically
imperfect shells [5, 8] were imported into
MATLAB, treated as random fields and their
evolutionary power spectrum determined. The
evolutionary power spectrum was then used in
conjunction with the spectral representation method
to generate 50 Monte-Carlo computational models
of random imperfect 2D shell surfaces [10, 11].
Under the constraints of the evolutionary power
spectrum, these surfaces fit within the statistical
margins of the initial tested shells. The power
spectrum is described as the Fourier transform of the
auto-correlation function , and may be Fig 2. Bi-dimenional random field generated using the
spectral representation method.
interpreted as the distribution of the mean square of
the random field over the space-frequency The spectral representation method generates new
domain [11]. The evolutionary power spectrum was imperfect surfaces based about a common mean or
decomposed into two unrelated functions for the average value. Having passed the Kolmogorov-
frequency content and the spatial evolution based on Smirnov test (KS-test), which was used to check
the surfaces’ eligibility to utilize the method of whether the distribution of any small statistical
separation. This method allows an accurate series can be approximated by a normal distribution
estimation of the evolutionary power spectrum with [12], measured average radii of the cylinders, among
a reduced data set and is given as [11]: other variables, were confirmed to conform to a
Gaussian normal distribution with the parameters
, (1)
shown in Table 2.
where the estimated homogenous Fourier spectrum Table 2. Gaussian parameters of CFRP cylinders.
is:
1 Parameter Mean (mm) Standard Dev. %
(2) Radius 250.743 0.014
2
Total 0.478 2.699
and the estimated spatial envelope is: Thickness
| | The values in Table 2 were then used to generate 50
. (3) different mean radii and thickness values which
2
were incorporated into the 50 FE simulations.
The Hamming window was used to reduce the 3.2 Thickness Imperfections
window-processing loss energy bias. For a bi-
dimensional random field, the spectral Automated ultrasonic tests on the actual cylinders
representation method is [11]: were conducted by DLR using the water split
coupling echo-technique to detect any defects in the
structure; such as delaminations or air pockets [5].
, √2 Thickness imperfections were also recorded using
(4) this technique and imported into the spectral
representation method to create 50 stochastic models
with various correlated thickness measurements; an
where example of which is shown in Figure 3.
2 , , , ∆ ∆ . (5)
3
Translation <0,0,-0.7> (mm) The material properties displayed in Table 3 were
Rotation <,,,>
incorporated into MATLAB to generate 50 different
material properties for the stochastic simulations.
Variations in material properties are often much
higher in composite shells than those manufactured
from isotropic materials. Such variations are
unavoidable using modern manufacturing techniques
and arise from the intrinsic anisotropy of composite
materials [13]. From the DLR ultrasonic scans and
Figure 3, it is evident that some points with the
lowest thicknesses are situated along the fibre
directions; particularly the outermost -41º ply. These
aligned points can be interpreted as a gap between
plies in that particular direction which was not
adequately closed during fabrication [10]. These
areas therefore possess different localized material
properties.
Translation <0,0,0>
Rotation <,,,> An automated routine [10] was followed in order to
pinpoint aligned areas where inter-ply gaps may
Fig. 3. FE model featuring boundary conditions and
exist. Firstly, all points that were characterized as
thickness imperfections generated from the spectral
representation method. the absolute lowest thickness value were selected as
candidate gap points. If the points were aligned in
In addition to the spectral representation method, the ply directions and exceeded a certain threshold, set
means of the thickness imperfections for each at one-fifth the total number of points in the ply
cylinder were varied according to the Gaussian direction, a missing ply was assigned to these points.
distribution in Table 2. Otherwise, they were modeled by a reduction in the
3.3 Material Imperfections matrix phase only.
The shim used was a thin metal plate with a and the difference between the magnitude of the
thickness that varied from t = 0.05mm to t = 0.4mm. different imperfection types (input) and their
It was located between the top and the end plate at average values were plotted into metamodels and
32 predefined and equally spaced positions on the their sensitivities defined using the following
circumference and provided the stochastic input into formula [9]:
these simulations.
∑
(6)
To represent the above loading imperfections in ∑
MSC.Patran, an uneven “initial displacement” was
applied over the upper edge of the cylinders, where where β is the “sensitivity” of the output with
the maximum initial displacement corresponded to respect to a given input,
the various thicknesses of the metal shim; an m is the number of stochastic inputs,
example of which is shown in Figure 5. is the output response,
is the input variable; and,
Max the over-bar indicates the mean value.
displacement
(0.05-0.4mm) The values of the sensitivities were scaled and
Shim thickness normalized to remove skew effects originating
from the different fundamental units of the
Min displacement stochastic inputs [15]. The sensitivity points to the
(0mm)
amount of change that the output result experiences
with respect to a change in the input variable. Thus,
a large Sensitivity translates to a large change in
output, as the input is varied. This is shown in
Figure 6 where plots showing various levels of
sensitivity are shown. Note that Sensitivity can also
be interpreted as the gradient of the line of best fit
for any given metamodel.
1 Low Sensitivity 1 High Sensitivity
Fig. 5. Load imperfection simulation in MSC.Patran.
Output Variable/
Buckling Load
Buckling Load
5
linearly related. The formulation for the Influence ρ
is:
1
∑
2 (7)
1 1
∑ ∑
2 2
30 30
28 28
26 26
22 22
20 20
18 18
16 16
14 Spectral 14
12 Actual 12
Spectral
10 10
-0,1 -0,05 0 0,05 0,1 145 150 155 160 165 170 175
Difference from Average Radius (mm)
Longitudinal Compression Modulus (GPa)
Fig. 9. Effect of geometric imperfections on axial Fig. 12. Effect of longitudinal compression modulus
buckling load. imperfections on axial buckling load.
30
30
28
28
26
26
24
Buckling Load (kN)
24
Buckling Load (kN)
22
22
20
20
18
18
16
16
14 Spectral
14
12 Actual
12
10 Spectral
-0,06 -0,04 -0,02 0 0,02 0,04 0,06 10
Difference from Average Thickness (mm) 8,5 9 9,5 10 10,5 11 11,5
Transverse Compression Modulus (GPa)
Fig. 10. Effect of thickness imperfections on axial
Fig. 13. Effect of transverse compression modulus
buckling load.
imperfections on axial buckling load.
30
30
28 Spectral
28
26
26
24
Buckling Load (kN)
24
Buckling Load (kN)
22
22
20
20
18
18
16
16
14
14
12
12 Spectral
10
0 0,1 0,2 0,3 0,4 0,5 10
Shim Thickness (mm) 5,15 5,2 5,25 5,3 5,35 5,4 5,45
Shear Modulus (GPa)
Fig. 11. Effect of loading imperfections on axial buckling
Fig. 14. Effect of shear modulus imperfections on axial
load.
buckling load.
7
30 and boundary conditions had the largest overall
28 influence. Thickness imperfections, the longitudinal
26 Young’s modulus and deviated fibre angles caused a
24 further load reduction. From investigations on
Buckling Load (kN)
the validity of this approach across a range of [8] C. Hühne, R. Zimmerman, R. Rolfes, B. Geier.
different important structural designs. The “Sensitivities to geometrical and loading
correlation of the imperfections to the torsional imperfections on buckling of composite cylindrical
buckling load may also emerge as an important shells”. Rep. Germany: German Aerospace Centre,
Braunschweig, Institute of Structural Mechanics,
research topic
2002.
Furthermore, variations in fibre angle were not [9] M. Lee. “Stochastic analysis and robust design of
accounted for in this paper and should be an area for stiffened composite structures”. Diss. The University
future research. of New South Wales, 2009. Sydney: UNSWorks,
2009.
8 Conclusion [10] M. Broggi, G. Schuëller. “Accurate prediction of the
Methods have been developed to accurately compare statistical deviations of the buckling load of imperfect
CFRP cylindrical shells”. In: IV European
the overall effect of the axial buckling load to
Conference on Computational Mechanics. Paris,
different imperfection types. The results indicate that France, EU, 2010.
thickness imperfections hold the most influence over [11] D. Shillinger, V. Papadopoulos. “Accurate estimation
the axial buckling load than others and must be of evolutionary power spectra for strongly narrow-
accounted for in the design process. Many more band random fields”. Computer Methods In Applied
stochastic and probabilistic data are necessary to Mechanics And Engineering, Vol. 199, No. 17-20, pp
validate this approach. Such results may be used to 947-960, 2010.
aid the design of more robust, lightweight and cost- [12] I.M. Chakravarti, R.G. Laha, J. Roy. Handbook of
effective shells if used in collaboration with the methods of applied statistics. John Wiley and Sons;
Robust Index Methodology developed in previous Vol. 1, pp 392-4, 1967.
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