Interlaminar Modelling To Predict Composite Coiled Tube Failure
Interlaminar Modelling To Predict Composite Coiled Tube Failure
Interlaminar Modelling To Predict Composite Coiled Tube Failure
Siamak
coiled tube failure Mishani
Mode-I testing for pure normal stress, (GII) in Mode-II test- two independent failure modes in unidirectional fibre com-
ing for pure shear stress, and (GIII) for pure sliding stress. As posites: fibre failure and inter-fibre failure. In the fibre failure
shown in Equation 2, the total strain energy release rate (GT) mode, composite material fails due to a rupture resulting from
expresses the total pure strain energy release rates from nor- a tension force and buckling from a compressional force. Ma-
mal, shear and sliding stresses. Interlaminar fracture tough- trix (inter-fibre) failure occurs in a plane parallel to the fibres
ness shows the resistance of composite materials to delami- (Hashin, 1980).
nation (Thakur, 2013); therefore, it is an important composite Unidirectional fibre composites are transversely isotropic
property and widely acknowledged by designers. in the fibre direction; therefore, fibre-reinforced failure modes
consider the uni-axial stress state in the fibre direction, while
GT = GI + GII + GIII (2) matrix failure modes consider the tri-axial stress state.
Hashin’s failure criteria involved four failure modes for fi-
Ply-by-ply mathematical modelling and numerical simula- bres and matrices (Hashin, 1980):
tions were developed to predict interlaminar delamination of 1. tensile fibre failure for σ11 ≥ 0;
filament-wound composite coiled tubes. Fracture test models 2. compressive fibre failure for σ11 < 0;
such as the double cantilever beam (DCB) and end-notched 3. tensile matrix failure for σ22 + σ33 ≥ 0; and,
flexure (ENF) models can be used to extract fracture param- 4. compressive matrix failure for σ22 + σ33 < 0.
eters.
Three-dimensional commercial finite element software— Interlaminar fracture (delamination)
ANSYS/APDL version 15.0—was used for all simulations. The
virtual crack closure technique (VCCT) and cohesive zone Three crack propagation failure modes of delamination are
model (CZM) were used to determine delamination growth shown in Figure 3 for interlaminar crack displacements. The
in an initially delaminated composite model. The finite ele- numerical simulation of the crack propagation follows two
ment model was evaluated under a combination of different procedures. The first is based on fracture mechanics, and the
loading scenarios. A comparison between the crack propaga- second is based on a mixture of damage mechanics and soften-
tion in glass- and carbon-fibre in composite material was then ing plasticity (Spada et al, 2009).
performed. The mechanical parameters indicate that delamination hap-
pens through the interface layer. The resistance of the interface
Hashin’s failure criteria for unidirectional fibre to propagate the interlaminar crack under the opening mode
composites (Mode-I) is different from under the shear mode (Mode-II).
The increase of force applied in Mode-I and Mode-II gives rise
One of the critical problems in the design and modelling of to tensile and shear stresses at the delamination crack front,
fibre-reinforced composite material under cyclic loading is to respectively (Mathews and Swanson, 2007).
establish meaningful fatigue failure criteria. There are many A delamination crack propagates when the strain energy
failure criteria for the design and modelling of composite ma- release rate is equal to or greater than the value of the critical
terial (Barbero, 2013). energy release rate (Alfano and Crisfield, 2001).
Hashin (1980) proposed a failure criterion for unidirec-
tional fibre-composite materials based on quadratic stress Crack opening mode (Mode-I)
polynomials. Hashin’s failure criteria indicated that there are
According to Wisheart and Richardson (1998), the strain
energy release rate can be statically measured using a DCB
test for Mode-I delamination. The model is designed with a
pre-existing crack. By applying an opposite direction force to
the end of the sample, perpendicular to the crack surface, the
pre-existing crack will extend. Figure 4 shows the crack geom-
etry, the reaction forces and crack displacements. The reaction
forces are calculated according to Equation 3 and the resul-
tant crack displacements are used to calculate the total frac-
ture toughness energy (GI). A schematic diagram of the DCB
is shown in Figure 5.
1
GI = R dv (3)
2 da y
Figure 3. Crack growth modes: (a) opening Mode-I; (b) sliding shear Mode-II; and,
Figure 2. Meso-scale damage model of a laminate (Bordeu and Boucard, 2009). (c) scissoring shear Mode-III (Van Mier, 2012).
DCB (Mode-I) a crack front; however, it cannot predict the initiation of the
interlaminar crack. Mesh size and material parameters are im-
The crack opening mode (Mode-I) test is generally portant factors in CZM modelling. The interface between the
performed on a unidirectional composite laminate specimen. adjacent layers of the composite structure is properly defined
In this method, the applied load versus crack displacement is to determine the crack propagation. The CZM is considered to
linear, and the first deviation from linearity occurs as the crack be a tool to evaluate the deterioration of cohesion between the
initiation happens. According to fracture mechanics concepts, layers, which uses the relationship between the separation and
the propagation from a pre-existing delamination can be traction along the interface. Table 1 shows the strengths and
calculated by the amount of strain energy release rate and the weaknesses of the CZM and CVVT modelling methods.
fracture toughness of the interface (Choupani, 2008).
The interlaminar fracture toughness calculations are based Interface
on Equation 4 (Prasad et al, 2011).
The laminated interface is a 3D medium and its thickness is
negligible compared to the laminated specimen dimensions;
3 Pδ (4)
GI = therefore, modelling the interface layer is defined as a 2D entity
2ba to evaluate the relative displacement and reaction force from
one layer to the next. Due to low-strength bonding between the
Crack sliding mode (Mode-II) adjacent layers, the interface offers the best path for the crack
to propagate. The interface strength only depends on matrix
Mode-II delamination failure is a method for measuring properties.
shear stresses at the crack tip. A three-point bending load on
the ENF specimen with a pre-existing crack (a, as shown in
Fig. 6) can determine the strain elastic release energy rate. The
pre-existing crack propagates as the bending load is applied
to the specimen. The finite element model was designed to
simulate a sample similar to the set up shown in Figure 6. Ac-
cording to Equation 5, the total fracture toughness energy (GII)
is calculated from the reaction force at the crack tip, load point
displacement and the crack propagation length.
1
GII = R du (5)
2 da x
ENF (Mode-II)
The ENF test is a method for measuring interlaminar fracture
toughness in composite materials under in-plane shear stress.
The crack sliding mode (Mode-II) is a type of fracture testing
method in which the crack initiation and propagation’s front
faces slide on each other in the direction of the crack’s growth
path and no crack opening mode occurs (Salehizadeh and Saka, Figure 4. 2D crack geometry of the DCB (Krueger, 2004).
1992). Mode-II interlaminar fracture toughness is calculated
according to Equation 6 and is denoted by GII (Zhu, 2009).
9P2a2
GII = (6)
16E11b2h3
FINITE ELEMENT MODELLING To simulate Mode-I (the opening mode), one end of the DCB
structure was fixed. The opposite free end (with the pre-exist-
To study the effect of crack initiation and propagation behav- ing crack) was subjected to a total of 20 mm of displacement,
ior, a glass-fibre composite material and a carbon-fibre com- as shown in Figure 5. For Mode-II (the sliding shear mode), a
posite material were modelled. The two approaches, VCCT and three-point loading was simulated, similar to the ENF model.
CZM, were implemented in the finite element analysis software Both ends of the sample were supported on one side, and on
(ANSYS/APDL version 15). The applied load modes evaluated the opposite side to the sample a 10 mm displacement was
were opening Mode-I using the DCB design according to ASTM exerted through the point load at the centre, as illustrated in
D5528, and shear Mode-II using the ENF design according to JIS Figure 6. The 3D zero thickness interfaces were modelled as an
K7086 standards. The strain energy release rates—GI and GII— inter-layer cohesive element between the laminate to direct the
due to normal and shear stresses, respectively, were evaluated. interlaminar crack propagation front paths.
Figure 7. ANSYS model von-Mises stress distribution (N) for (a) ENF and (b) DCB.
Figure 9. Energy release rates (Mode-II) for (a) carbon fibre and (b) glass fibre.
Figure 10. Mode-I DCB testing for (a) carbon fibre and (b) glass fibre.
Figure 11. Mode-II ENF testing for (a) carbon fibre and (b) glass fibre.
CONCLUSIONS REFERENCES
This paper presents the initial results of a study into the in- ALFANO, G. AND CRISFIELD, M., 2001—Finite element in-
fluence of failure on the properties of filament-wound coiled terface models for the delamination analysis of laminated
tubes. Numerical simulation was implemented in ANSYS/APDL composites: mechanical and computational issues. Interna-
software to measure the delamination fracture toughness of tional Journal for Numerical Methods in Engineering, 50 (7),
carbon- and glass-fibre composite laminates. The variation of 1,701–36.
strain release energy rates versus crack tip in Figures 8 and 9
illustrate that the 2D modelling cannot express the real release ANSYS®, 2013—ANSYS Mechanical User’s Guide. Release 15.0
strain energy rate at the crack front tip. The contour for GI in- Canonsburg, Pennsylvania: ANSYS, Inc.
creases—almost doubling in value—from the edge to the cen-
tre (from 5 J/m2 to approximately 10.2 J/m2), while GII slightly BARBERO, E.J., 2013—Finite element analysis of composite
decreases from the edge to the centre (from 10.4 to 9.9 J/m2). It materials using ANSYS®. Second edition. Boca Raton, Florida:
is, therefore, necessary to investigate the crack propagation in CRC Press.
composite laminates using 3D modelling.
According to Figures 10 and 11, the applied load to load dis- BORDEU, F. AND BOUCARD, P., 2009—A mesoscale model
placement perpendicular to the crack plane for carbon fibre is for the prediction of composites materials until final failure.
almost three times more than that for glass fibre in Mode-I and Proceedings of ICCM-17 17th International Conference on
Mode-II. The observations are similar to those of Williams (1988) Composite Materials, 27–31 July, Edinburgh, UK.
in that the Mode-II interlaminar fracture toughness of compos-
ite laminate is several times higher than Mode-I interlaminar BRUNNER, A., BLACKMAN, B.R.K. AND DAVIES, P., 2008—A
fracture toughness in the same material. Also, the DCB testing status report on delamination resistance testing of polymer–
method (opening mode for normal stress) presents the weakest matrix composites. Engineering Fracture Mechanics, 75 (9),
type of interlaminar delamination failure in composite materials. 2,779–94.
PRASAD, M.S., VENKATESHA, C.S. AND JAYARAJU, 2011—Ex- THAKUR, V.K., 2013—Green composites from natural resourc-
perimental methods of determining fracture toughness of fiber es. Boca Raton: Florida. CRC Press.
reinforced polymer composites under various loading condi-
tions. Journal of Minerals and Materials Characterization and VAN MIER, J.G.M., 2012—Concrete fracture: a multiscale ap-
Engineering, 10 (13), 1,263–75. proach. Boca Raton, Florida: CRC Press.
REIFSNIDER, K., HENNEKE, E.G., STINCHCOMB, W.W. AND WILLIAMS, J., 1988—On the calculation of energy release rates
DUKE, J.C., 1983—Damage mechanics and NDE of composite for cracked laminates. International Journal of Fracture, 36 (2),
laminates. In: Hashin, Z. and Herakovich, C.T. (eds) Mechanics 101–19.
of Composite Materials: Recent Advances. New York: Pergamon
Press, Inc. WISHEART, M. AND RICHARDSON, M., 1998—The finite ele-
ment analysis of impact induced delamination in composite
SALEHIZADEH, H. AND SAKA, N., 1992—Crack propagation materials using a novel interface element. Composites Part A:
in rolling line contacts. Journal of Tribology, 114 (4), 690–7. Applied Science and Manufacturing, 29 (3), 301–13.
SPADA, A., GIAMBANCO, G. AND RIZZO, P., 2009—Damage WU, F. AND YAO, W., 2010—A fatigue damage model of com-
and plasticity at the interfaces in composite materials and posite materials. International Journal of Fatigue, 32 (1), 134–8.
structures. Computer Methods in Applied Mechanics and En-
gineering, 198 (49), 3,884–901. ZHU, Y., 2009—Characterization of interlaminar fracture tough-
ness of a carbon/epoxy composite material. Master of Science
SUN, X., TAN, V.B.C., LIU, G. AND TAY, T.E., 2009—An enriched thesis, 15 July 2008. University Park, Pennsylvania: The Penn-
element-failure method (REFM) for delamination analysis sylvania State University.
of composite structures. International Journal for Numerical
Methods in Engineering, 79 (6), 639–66. Authors' biographies next page.
THE AUTHORS
Soren Soe is DET CRC’s leader for Peter Jaensch received his BEng degree
Project 1.1: Next Generation Drilling in mechanical engineering from the
Technologies. Soren has held various University of South Australia in 1997.
project, engineering and executive Since 1990 Peter has worked for a
leadership positions since completing number of organisations—primarily in
his Bachelor of Science degree in research and product development—in
engineering in 1991. fields such as automotive components,
He has worked extensively with special purpose machinery, printing
leading the development of onshore industry new technologies, equine
drilling rigs for mineral exploration, production holes, racing equipment, beef abattoir equipment, and mineral
geotechnical applications and coiled tubing rigs for the oil exploration drilling equipment.
and gas industry. Peter started with Boart Longyear in June 2010 and he
During his career, Soren has expatriated to China, The lead the engineering team in the development of the LX12
Netherlands and Poland with such companies as Knebel multipurpose drill rig.
Drilling A/S, Boart Longyear and A.P. Moller-Maersk. Peter has been with DET CRC’s Project 1.1 since September
sorensoe@detcrc.com.au 2013 to develop the composite drill to a point where the
torsional load and axial load capabilities are adequate for
typical drilling operations.
peter.jaensch@boartlongyear.com