Sequentially Coupled Material Flow and Multi-Scale Stress Analysis of Discontinuous Long-Fiber
Composite Helicopter Fairing Rib
M.H. Kilic, J.H. Han
Greene, Tweed & Co., Kulpsville, U.S.A.
S.R. O’Neill, Greene, Tweed & Co., Nottingham, United Kingdom
Discontinuous long-fiber (DLF) thermoplastic composites have been developed to replace complex-shaped metal parts. However, due to the random fiber structure of the material, analysis and prediction of part performance had been a challenge in the past. A sequentially coupled material flow and micromechanics-based multi-scale stress analysis is presented for the fiber orientation, nonlinear and progressive damage analyses of a compression molded DLF composite aerodynamic fairing rib for the landing gear skid of an eco-friendly helicopter. Predicted fiber orientation distributions obtained from the processing simulation tool are transferred to the corresponding finite
element (FE) model for stress analysis. A three-dimensional nonlinear micromechanical material model is implemented as a material subroutine to the FE analysis tool. The sequentially coupled analysis approach shows very good predictive capabilities for the fiber orientation distributions, nonlinear response, and ultimate load of the DLF composite rib. The DLF composite rib offered a 55% weight saving compared to the original metallic design along with the reduced machining operations.
ITHEC 2016 Manuscript B4
Publication date: 01/10/2016
Manuscript B4 published in Conference Proceedings ITHEC 2016
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