PSI - Issue 42

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ScienceDirect

Procedia Structural Integrity 42 (2022) 1328–1335 Structural Integrity Procedia 00 (2019) 000–000 Structural Integrity Procedia 00 (2019) 000–000

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© 2022 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of the scientific committee of the 23 European Conference on Fracture – ECF23 Abstract The integrity of the composite structures is a ff ected by the manufacturing conditions. Controlling the ply orientation during the manufacturing process plays an important role in defining the induced residual stresses inside the laminate. This work evaluates the generated residual stresses inside multi-axis laminates of carbon fiber reinforced polymers. The samples are manufactured using the robotic fiber placement technique. The residual stresses are measured through the incremental hole-drilling method. Finite element modeling is used to provide the calibration process of the strain measurements. Additionally, microstructure analyses have been performed to show the configuration of the manufactured samples. The e ff ect of the laminate configurations and plies orientations are investigated and compared. The layers’ orientations have shown a considerable e ff ect on the generated stresses. 2020 The Authors. Published by Elsevier B.V. is is an open access article under the CC BY-NC-ND license (http: // creativecommons.org / licenses / by-nc-nd / 4.0 / ) er-review under responsibility of 23 European Conference on F acture – ECF23 . Keywords: Multi-axis composites; Residual stresses; Carbon fiber; Robotic fiber placement. 23 European Conference on Fracture – ECF23 Study of the Automated Process-Induced Residual Stresses in Multi-Axis Laminates Mohamed M.A. Ammar a,b, ∗ , Bijan Shirinzadeh a a Robotics and Mechatronics Research Laboratory, Department of Mechanical and Aerospace Engineering, Monash University, Clayton 3800, Australia b Department of Mechanical Engineering, Faculty of Engineering, Alexandria University, Alexandria 11432, Egypt Abstract The integrity of the composite structures is a ff ected by the manufacturing conditions. Controlling the ply orientation during the manufacturing process plays an important role in defining the induced residual stresses inside the laminate. This work evaluates the generated residual stresses inside multi-axis laminates of carbon fiber reinforced polymers. The samples are manufactured using the robotic fiber placement technique. The residual stresses are measured through the incremental hole-drilling method. Finite element modeling is used to provide the calibration process of the strain measurements. Additionally, microstructure analyses have been performed to show the configuration of the manufactured samples. The e ff ect of the laminate configurations and plies orientations are investigated and compared. The layers’ orientations have shown a considerable e ff ect on the generated stresses. © 2020 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (http: // creativecommons.org / licenses / by-nc-nd / 4.0 / ) Peer-review under responsibility of 23 European Conference on Fracture – ECF23 . Keywords: Multi-axis composites; Residual stresses; Carbon fiber; Robotic fiber placement. 23 European Conference on Fracture – ECF23 Study of the Automated Process-Induced Residual Stresses in Multi-Axis Laminates Mohamed M.A. Ammar a,b, ∗ , Bijan Shirinzadeh a a Robotics and Mechatronics Research Laboratory, Department of Mechanical and Aerospace Engineering, Monash University, Clayton 3800, Australia b Department of Mechanical Engineering, Faculty of Engineering, Alexandria University, Alexandria 11432, Egypt

1. Introduction 1. Introduction

The fibrous composites and in particular carbon fiber have become popular in di ff erent advanced structural designs Bajaj et al. (2020). Therefore, there is a need to understand their mechanical behavior and their relationship with the manufacturing conditions to improve the final characteristics. The production of the composite laminates includes applying mechanical and thermal loads in order to obtain the final components Ammar et al. (2022); Ammar and Shirinzadeh (2022b); De Gracia et al. (2018); Daniel and Liber (1977). The applied loads in conjunction with the laminate compositions as well as their configurations are believed to have an impact on the product’s final mechanical properties. The induced residual stresses are from the main e ff ect of the subjected mechanical and thermal loads Lubineau (2008); Gurova et al. (2019); Karakuzu et al. (2004); Kaddour et al. (2003). The fibrous composites and in particular carbon fiber have become popular in di ff erent advanced structural designs Bajaj et al. (2020). Therefore, there is a need to understand their mechanical behavior and their relationship with the manufacturing conditions to improve the final characteristics. The production of the composite laminates includes applying mechanical and thermal loads in order to obtain the final components Ammar et al. (2022); Ammar and Shirinzadeh (2022b); De Gracia et al. (2018); Daniel and Liber (1977). The applied loads in conjunction with the laminate compositions as well as their configurations are believed to have an impact on the product’s final mechanical properties. The induced residual stresses are from the main e ff ect of the subjected mechanical and thermal loads Lubineau (2008); Gurova et al. (2019); Karakuzu et al. (2004); Kaddour et al. (2003).

∗ Corresponding author. ORCID: 0000-0002-8737-1001. E-mail address: Mohamed.ammar@monash.edu ∗ Corresponding author. ORCID: 0000-0002-8737-1001. E-mail address: Mohamed.ammar@monash.edu

2452-3216 © 2022 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of the scientific committee of the 23 European Conference on Fracture – ECF23 10.1016/j.prostr.2022.12.169 2210-7843 © 2020 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (http: // creativecommons.org / licenses / by-nc-nd / 4.0 / ) Peer-review under responsibility of 23 European Conference on Fracture – ECF23 . 2210-7843 © 2020 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (http: // creativecommons.org / licenses / by-nc-nd / 4.0 / ) Peer-review under responsibility of 23 European Conference on Fracture – ECF23 .