J Fail. Anal. and Preven.

(2022) 22:633–647
https://doi.org/10.1007/s11668-022-01346-4

TECHNICAL ARTICLE—PEER-REVIEWED

Continuum Damage Mechanics Model for Damage assessment

and Strength Prediction in Laminated Composite Structures
N. Subramanyam . R. Vijayakumar . K. Prahlada Rao

Submitted: 12 September 2021 / in revised form: 9 January 2022 / Accepted: 11 January 2022 / Published online: 12 February 2022
Ó ASM International 2022

Abstract This paper examines the continuum damage Introduction

model to predict the strength and size effects of polymer
composites, deformation and failure response when sub- The use of advanced analytical or numerical models for the
jected to complex states of stress. The prediction of size prediction of the mechanical behavior of composite struc-
effects for a notched composite plate under uniaxial tension tures can replace some of the mechanical tests and can
is carried out. This study aims to extend the proposed significantly reduce the cost of designing with composites
continuum damage model to evaluate ultimate strength and while providing to the engineers the information necessary
damage progression to predict the failure around stress to achieve an optimized design. Moreover, the continuum
concentration regions accurately. The finite element-based damage model does not require any calibration and it is
continuum damage mechanics model can be applied to the applicable to general geometries and boundary conditions.
structures and components of arbitrary configurations The evaluation of ultimate strength remains the main
where analytical solutions could not be developed. The challenge in the simulation of the mechanical response of
present work also considers how the overall results of the composite materials [1]. Analytical techniques have been
exercise can be used in design applications for the pre- used for predicting the size effects in flat composite lami-
diction of ultimate strength and mechanical response of nates at different material and structural levels subjected to
composite structures considering the continuum damage uniaxial loads [2–4].
mechanics model as a design tool. Introduction of advanced laminated composite materials
to aircraft structural applications has led to accurate ana-
Keywords Continuum damage mechanics model  lytical and computational tools development that can
Finite element model  Square  Rectangular cut-out  predict the thermo-mechanical response and damage tol-
Progressive damage  Failure stress erant design approaches for composite structures under
general loading conditions and geometries. The size effect
is usually called the ‘‘in situ’’ effect and can be accounted
for in predicting matrix-cracking onset using the ‘‘in situ’’
strengths inappropriate failure criteria. The ‘‘in situ’’
strengths can be calculated from analytical closed-form
solutions using ply elastic properties and fracture energies
[5, 6].
N. Subramanyam  K. P. Rao
The term ‘‘progressive damage’’ refers to spatial pro-
Department of Mechanical Engineering, Jawaharlal Nehru gression. The available damage evolution law in ANSYS is
Technological University JNTUA, Anantapuramu 515002, India Material Property Degradation (MPDG) Method, which is
an instant stiffness reduction. Thus, once the stress reaches
R. Vijayakumar (&)
Rotary Wing R & D Centre, Hindustan Aeronautics Limited,
the damage limit, the material stiffness is immediately
Bangalore 560017, India reduced to a user-specified value. In this case, damage can
e-mail: rayavarapu.rvk@gmail.com

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634 J Fail. Anal. and Preven. (2022) 22:633–647

progress through the model into other elements in the mesh composites under general loads and boundary conditions
as the load is increased, but the damage within a particular for which no analytical solution is available. The contin-
element is modeled as a step function: either undamaged or uum damage model used here is based on previous work by
damaged. An additional damage evolution law called the the authors [7, 8, 21]. The main aim of the continuum
Continuum Damage Mechanics (CDM) Method available damage model is presented below.
in ANSYS. In this model, damage variables increase Constitutive model:
gradually based on energy amounts dissipated. Damage can The proposed definition for the complementary free
therefore progress within an element as well as throughout energy density of a ply is given in Eq. 1
the mesh. r211 r222 m12
Intra-ply damage modes have been investigated pri- G¼ þ  r11 r11
2ð1  d1 ÞE1 2ð1  d2 ÞE2 E1
marily within the Continuum Damage Mechanics (CDM)
r212
[7–9]. In contrast, delamination has been studied exten- þ þ ða11 r11 þ a22 r22 ÞDT
2ð1  d6 ÞG12
sively using interface fracture modeling techniques such as
þ ðb11 r11 þ b22 r22 ÞDM ðEq 1Þ
cohesive zone models and virtual crack closure techniques
(VCCT) [10, 11]. The transverse strength of 90 plies The damage variable d1 is associated with longitudinal
located in cross-ply laminates subjected to transverse ten- (fiber) failure, d2 is the damage variable associated with
sion is investigated by numerical analysis [12]. The impact transverse matrix cracking, and d6 is the damage variable
of the layer thickness and the presence of micro tubes on related to longitudinal and transverse cracks. b11 and b22
the in situ strength of the 90° layer and the influence of are the coefficients of hygroscopic expansion in the
induced delamination on the strength of [0/90n/0] laminates longitudinal and transverse directions, respectively. DT
in micro and macro scales is investigated [13]. The effects and DM are the differences in temperature and moisture
of matrix crack formation on the properties of composite content concerning the corresponding reference values.
laminates subjected to bending loads, are studied analyti- The coefficients of thermal expansion of a ply are also
cally using a crack density-based model [14]. The affected by the failure mechanisms. The exact dependence
progressive damage formation in open-hole laminated of the coefficients of thermal expansion with damage can
composites subjected to axial tensile and compressive be obtained for simple laminates in the absence of stress
loading using a constitutive model is investigated [15]. A gradients [22]. The strain tensor is equal to the
new Integrated Micro-Macro (IMM) approach is proposed complementary free energy density derivative concerning
to consider the impact of debonding and its induced ma- the stress tensor as given in Eq. 2.
trix-cracking on the macro response of composite oG
laminates [16] Despite these advances in progressive e¼ ¼ H : r þ aDT þ bDM ðEq 2Þ
or
damage modeling, [17–20] have suggested that CDM
models for ply failure, coupled with cohesive zone models The lamina compliance tensor can be represented as in
for delamination, have difficulty accurately representing Eq. 3
2 1 3
laminate failure sequences that exhibit strong coupling
2 ð1d1 ÞE1  mE121 0
oG 6
between transverse matrix-cracking and delamination.
H ¼ 2 ¼ 4  E121
m 1
ð1d2 ÞE2 0 7 5 ðEq 3Þ
The present work investigates the mechanical responses or 1
0 0 ð1d6 ÞG12
of continuous fiber-reinforced composites by modifying
and extending the available micromechanical framework. Intra-laminar Damage:
A significant part of the work conducted involves analyz- The continuum damage mechanics model implemented
ing the effective damage responses due to damage to simulate intra-laminar damage is available for elements
evolutions of matrix micro cracks and fiber breakages. with a plane stress formulation and is intended to predict
elastic-brittle materials that show no appreciable plastic
deformation before failure. Four failure modes, including
Continuum Damage Mechanics Model fiber tension, fiber compression, matrix tension and matrix
compression, are considered and are represented sepa-
Strength-based failure criteria are commonly used in the rately. The most important among the proposed criteria is
finite element method to predict failure events in composite Hashin’s criterion [23] assumes a quadratic interaction
structures. Many continuum-based standards have been between the stresses acting on the fracture planes. Initiation
derived to relate stresses and experimental measures of of damage, which refers to the onset of damage at a
material strength to the onset of failure. Continuum dam- material point, is based on Hashin’s theory.
age mechanics (CDM) is a methodology well suited for the
simulation of damage evolution and ultimate failure of

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The failure criteria included in the present work analyses failure modes in each ply and apply the corresponding
are those proposed by Hashin and are summarized. Matrix reduction in material stiffness.
Failures in tension and compression occurs due to a com-
bination of transverse stresses, r22, and shear stresses, s12.
The failure index defined in terms of these stresses and the Methodology
strength parameters. Failure occurs when the index exceeds
unity. The methodology for designing high-performance struc-
The Hashin Criteria for the four different failure modes tures of composites is still evolving. In recent years,
are described in Eqs. 4-7 as follows: ‘‘virtual testing’’ has increased in use to try new materials
Fiber tension ðr11  0Þ in structures earlier in an applications timeline. Virtual
r 2 s 2 testing is made possible by conducting progressive damage
11 12
Fft ¼ þa L ðEq 4Þ analysis and combining those results to predict struc-
XT S
ture/component safety based on the physics and
Fiber compression ðr11  0Þ micro/macro mechanics of materials, manufacturing pro-
r 2
11 cesses, available data and service environments. The
Ffc ¼ ðEq 5Þ
XC approach takes progressive damage and fracture processes
Matrix tension ðr22  0Þ into account and accurately assesses reliability and dura-
r 2 s 2 bility by predicting failure initiation and progression based
22 12
Fmt ¼ þ L ðEq 6Þ on constituent material properties. Such approaches are
YT S becoming more widespread and economically advanta-
Matrix compression ðr22  0Þ geous in some applications.
" #
 r 2  Y C 2 r22 s12 2
Evaluation of progressive damage technique requires a
c 22
Fm ¼ þ 1 þ L ðEq 7Þ definition of linear elastic orthotropic material and three
2ST 2ST YC S material models: Damage initiation criteria, Damage evo-
lution law and Material strength limits—selection criterion
In the above equations, rij are the components of the
for tensile, compressive failure and fiber and matrix. Cri-
effective stress tensor, and XT and XC are the longitudinal
teria include Maximum strain, Maximum stress, Puck,
tensile and compressive strengths, YT and YC are the
Hashin, LaRc03, LaRc04. User can also define up to 9
tensile and compressive strengths in the matrix direction,
user-defined criteria. Damage evolution defines how the
and SL and ST denote the longitudinal and transverse shear
material degrades following the initiation of damage. Set-
strengths. The coefficient a in Eq. 4 determines the shear
ting TBOPT = 1 sets the evolution law to the Material
stress contribution to the initiation of fiber tensile failure.
property degradation method (MPDG), which models
Once a damage initiation function is satisfied, the
instant stiffness reduction. The input to this law is the
associated damage variable is different from zero and
instant reduction factors for tensile and compressive stiff-
further loading will cause degradation of the material
ness in both tension and compression. The values can range
stiffness coefficients.
between 0 (no damage) and 1 (complete damage).
The stiffness matrix of a damaged ply is defined as in
Setting TBOPT = 2 sets the evolution law to the con-
Eqs. 8 and 9
tinuum damage mechanics method (CDM), which models
r ¼ Cd e ðEq 8Þ gradually increasing damage. The input to this law is the
2 3
ð1  d1 ÞE1 ð1  d1 Þð1  d2 Þm21 E2 0 energy dissipated per unit area and the viscous damping
14 5
Cd ¼ ð1  d1 Þð1  d2 Þm12 E2 ð1  d2 ÞE2 0 coefficient for each damage mode (8 constants total). The
D
0 0 ð1  d6 ÞG12 D damping coefficients are used to help overcome conver-
ðEq 9Þ gence difficulties that can occur for softening the material.
The Hashin failure criterion must be selected in the TB,
The damage evolution laws for the damage variables are
DGMI command.
defined in terms of the fracture energy dissipated during the
The values of the ply elastic properties are shown in
damage process. Methods for determining the fracture
Table 1. E1, E2 are the longitudinal and transverse Young’s
energies are provided in [24]. The damage evolution laws
need to ensure that the computed energy dissipated is
independent of the mesh. The energy dissipated for each Table 1 IM7/8552 Material Stiffness Properties
damage mechanism is regularized using the crack-band E11(GPa) E22 (GPa) G12 (GPa) m12
model. The failure analysis must be able to predict the
171.33 9.07 5.27 0.32

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636 J Fail. Anal. and Preven. (2022) 22:633–647

modulus, respectively, G12 is the shear modulus, and m12 is neighboring layers. To measure the components of the
the major Poisson’s ratio. The ply strengths are shown in fracture toughness, double cantilever beam (DCB) [2] and
Table 2. Xt and Yc are the longitudinal and transverse four points bending end notched flexure (4-ENF) tests were
tensile strengths, respectively. Yt and Yc are the longitu- performed. The continuum damage mode l(CDM) also
dinal and transverse compressive strengths, respectively. S requires the fracture energies per unit surface for longitu-
is the in-plane shear strength. This input is used to define dinal failure, G1? (tension) and G1- (compression).
the maximum stresses or strains that a material can sustain Energies dissipated per unit area (Gc) represents fracture
before damage occurs. The values to be input is based on toughness. Standard tests are used to obtain these values.
the damage initiation criterion selected. The strengths are These energies measured using the Compact Tension (CT),
calculated using the models proposed by the previous and Compact Compression (CC) tests proposed by Pinho
authors [4], based on mode I fracture toughness G2?, and et al. [25, 26]. The measured fracture energies per unit
on the mode II fracture toughness, G6 [6]. These models surface areas are shown in Table 3.
use the simplified assumption that the in situ strengths are The open-hole tension (OHT) specimen was studied
not a function of the geometry and elastic properties of the experimentally and computationally by P P Camanho, P
Maimi and C G Davila [27]. The progressive damage
analysis for the standard benchmark problem [9] of open-
Table 2 IM7/8552 Material Strength Properties
hole tension specimen was conducted in ANSYS using the
XT (MPa) XC (MPa) YT (MPa) YC (MPa) S (MPa) continuum damage mechanics model to represent the intra-
2325.6 1199.7 62.0 199.7 92.4 laminar damage modes (e.g., transverse matrix-cracking
and fiber failure) and cohesive elements to capture
delamination ply interfaces. The progressive damage
analysis of OHT specimens was carried out to quantify the
Table 3 IM7/8552 Fracture Energies (kJ/m2) size effect to validate the numerical model [9]. Good
G1C? (fiber) G1C- (fiber) G1C (matrix) G1IC (matrix) agreement was arrived between results from experimental
and numerical simulations. This agreement showed the
80.82 105.4 0.275 0.781
validity of the model. In quasi-isotropic laminates, Hexcel
IM7-8552 CFRP is considered as a ply material with a

Fig. 1 Typical FE model of Composite Plate [±45/02/90]s with Rectangular Cut-out, (a) Longitudinal cut-out, (b) Transverse cut-out

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Table 4 Illustration of Progressive Damage (Longitudinal cut-out: a/W=0.5)

b/W= 0.1 b/W= 0.2 b/W= 0.3 b/W= 0.4 b/W= 0.5
0
45 ply

(Fibre
Tension)

`-450 ply

(Fibre
Tension)

0
0 ply

(Fibre
Tension)

0
90 ply

(Matrix
Tension)

stacking sequence of [90/0/±45]3s. Specimens with five between the working and reference temperatures used to
different hole diameters d = 2 mm, 4 mm, 6 mm, 8 mm, 10 evaluate the residual thermal stresses were -155°C. In the
mm and a width to diameter ratio w/d = 6 are considered numerical analysis of progressive damage of notched
for the numerical studies. Further, the analysis has been laminate Shell181 elements are used to model 10-layer
extended to the problem of rotorcraft composite structures [±45/02/90]s composite laminate is considered. Thermal
for the investigation of the damage behavior by intra- and mechanical loading via applied displacements is
laminar and inter-laminar failure mechanisms. applied to capture the damage accumulation using appro-
priate failure criteria.
The structural response of the laminate with five dif-
Problem Statement ferent ratios of cut-out width to plate width (b/W = 0.1, b/
W = 0.2, b/W = 0.3, b/W = 0.4, b/W = 0.5) for a given a/
In the present work, the analyses have been carried out to W=0.5 is studied. From the numerical studies it is clearly
the problem of a composite plate containing rectangular/ observed that the effect of cut-out size on ultimate strength
square cut-outs under uniaxial tension (Fig. 1) for the can be explained using continuum damage model. Tables 4
investigation of the damage behavior by intra-laminar and and 5 illustrates the contour plot of Progressive Damage of
inter-laminar failure mechanisms. The typical FE model composite plate with Longitudinal cut-out and Transverse
proposed is illustrated in Fig. 1(a&b) is created using four- cut-out, respectively. The failure stresses are evolved in a
node structural shell element SHELL 181. The difference coupled manner before final failure. For all geometries,

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Table 5 Illustration of Progressive Damage (Transverse cut-out: a/W=0.5 )

b/W= 0.1 b/W= 0.2 b/W= 0.3 b/W= 0.4 b/W= 0.5
0
45 ply

(Fibre
Tension)

-450 ply

(Fibre
Tension)
00 ply

(Fibre
Tension)
00 ply

(Matrix
Tension)

there are several damage processes which influences the The geometry of rectangular composite plate with a
state of stress is illustrated in Tables 6 and 7. square/rectangular cut-out is shown in Fig. 4.
Figures 2 and 3 show the plot of the total reaction force The influence of cut-out size (d//b ratio) as well as
versus the applied displacement applied to the notched composite ply layup sequence on the ultimate failure load
composite plate [±45/02/90]s predicted using the consti- of a rectangular composite plate with a square/rectangular
tutive model proposed. The slope of the reaction force over cut-out is shown in Fig. 5.
the applied displacement curve decreases as the applied Hashin failure criterion is used to predict the ultimate
displacement increases. It is also observed that the laminate failure load in this analysis. Figure 4 indicates that the
with longitudinal rectangular cut-out the strength increases ultimate load decreases when the cut-out size increases,
by 25% compared to the laminate with transverse rectan- i.e., b/W ratio increases. For the composite plate [0/90]4s,
gular cut-out. The stress-strain behavior of laminate under as the cut-out size increases from b/W=0.1 to 0.2, 0.3 and
reaction force due to applied displacement was linear 0.4, the reduction in ultimate failure load is 12%, 39% and
elastic until first ply failure. From the typical load-deflec- 52%, respectively. From the Figure 4, it is also observed
tion curve it can be observed that the displacements are that, as the cut-out size increases from d/b=0.1 to 0.2, 0.3
evaluated, and the failure loads are predicted. The stress- and 0.4, the reduction in ultimate load is different for dif-
strain behavior of laminate under uniaxial tensile loads was ferent stacking sequences.
linear elastic until breakage and the slope of the total It can be seen that, [0/90]4s composite plate is stronger
reaction force over the applied displacement curve. Sub- than [0/?45/-45/90]2s, [75/-60/30/-15]2s, [-45/45]4s, [15/-
sequently, the behavior of laminate was nonlinear until 75]4s, [30/-60]4s composite plates. [0/90]4s composite
final failure occurred. This trend was observed for in both plate is strongest and [30/-60]4s composite plate is weakest
cut-out configurations. Table 8 shows illustration of stress than other analyzed laminated composite plates. Strength
distribution predicted by the model. The effects of cut-out of [0/90]4s composite plate is 12.6 times of the strength of
size d//b ratio (for b=00) with different ply configurations [30/-60]4s composite plate. [0/90]4s composite plate is
of the composite plate with a square/rectangular cut-out on 10.16, 5.18, 1.68 and 1.60 stronger than [-45/45]4s, [15/-
the ultimate failure load are further investigated. 75]4s, [0/?45/-45/90]2s and [75/-60/30/-15]2s, respectively.

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Table 6 Illustration of stress distribution (Longitudinal cut-out: a/W=0.5 & b/W=0.1)

(Sx) (Sy) (Sxy)

450 Ply

-450 Ply

00 Ply

900 Ply

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Table 7: Illustration of stress distribution (Transverse cut-out: a/W=0.5 & b/W=0.1)

(Sx) (Sy) (Sxy)

450 Ply

-450 Ply

00 Ply

900 Ply

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Fig. 2 Plot of the total reaction force vs. the applied displacement Fig. 4 Geometry Model
applied to the composite plate with Longitudinal cut-out (a/W=0.5)
Composite Material Modeling for Stress Analysis
of Rotor Blade

In this section, Continuum damage model has been

extended to the analysis of rotor blade for investigation of
damage behavior and complex state of stress. Helicopter
rotor systems are highly loaded structures with many
components made up of composites such as main and tail
rotor blades and rotor hubs. The wings or blades of a
helicopter are part of a rotor system, which is designed to
provide the lift, thrust and control. It is therefore apparent
that the safety of the helicopter is highly dependent on the
reliability of the rotor and its blades. The loads experienced
by the root end section of a main rotor blade during actual
Fig. 3 Plot of the total reaction force vs. the applied displacement
flight are flap load, lead-lag load, centrifugal load and the
applied to the composite plate with Transverse cut-out (a/W=0.5) torsion. The components of a civil helicopter need to be
certified according to the airworthiness guidelines con-
taining increased safety demands. The guidelines address
Table 8 List of Laminate ultimate stresses (a/W=0.5) subjects like an investigation of damages that may occur
from flight loads, residual strength requirements, consid-
(b/W) Ultimate (failure) stress, MPa at critical
ratio location at edge of hole eration of the effects of material variability and
Transverse environmental conditions like hot/wet strength degrada-
Longitudinal cut-out cut-out tion, etc.
0.1 760.39 560.66 The geometry of the main rotor blade with typical sec-
0.2 702.96 532.42
tion is shown in Fig. 6. It was modeled in Unigraphics NX,
0.3 632.45 510.29
imported into Ansys Workbench. The root of the main
rotor blade was repaired in Space claim and modeled along
0.4 555.14 49136
its span in Ansys Composite PrePost (ACP) of Ansys
0.5 475.23 475.23
Workbench through seamless integration of preprocessing
modules. The Ansys Workbench model is imported to

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Fig. 5 Influence of the d/b ratio on the ultimate failure load

GENOA MS-PFA for simulation under centrifugal, lead- carried out to assess the stress induced in the main rotor
lag, flap and torsion as a combined loading. Figures 7 and 8 blade with effect of ply-drop-off, and features at the
show more details about a typical section of the model, reduced skin thicknesses along the root end span.
total thickness map, offsets and all sections for the model. Figures 9 and 10 shows overall damage mechanisms for
The computational modeling approach is followed to the main rotor blade root end. They are split up into matrix
assess the damage and static strength from rotor loading by shear, matrix compression, matrix tension and fiber failure.
considering the effects of material variability to assess When a damage occurs, material degradation softens the
structural advantages of main rotor blade under service region and prevents other damages from happening. Here
loads. A micromechanics based multi-scale modeling matrix tension and shear seem to have prevented much
approach that detects damage and fracture evolution is matrix compression from happening. Figure 9 shows

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Fig. 6 Geometry model of Main Rotor Blade Root end

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Fig. 7 Shows the geometry model

Fig. 8 Plot of ply thickness along blade span

Fig. 9 Damage behavior of Rotor Blade Root end

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Fig. 10 Ply Damages in 176 plies for Fiber Failure (S11T) and Matrix Tensile Failure (S22T)

Fig. 11 Deformation of Rotor Blade Fig. 12 Normal Stress in fiber direction (s11)

matrix tension and fiber failure damages side by side within stress s12. The intra-laminar failure modes considered are
176 layers. Figure 11 shows the deformed behavior of rotor (i) Fiber failure in tension and compression (ii) Matrix-
blade. cracking in tension and compression. The stresses are
Figures 12, 13 and 14 shows the stress distribution, in computed in the principal material directions for each ply
fiber direction r11, matrix direction r22 and in-plane shear orientation and are used in the unidirectional failure

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nonlinear elastic relation between stress and strain under

tensile loads until final failure occurred catastrophically the
complex simulation tasks in terms of composite damage
modeling with inter- and intra-laminar failure modes
showed that FE codes are efficient and robust for the pre-
diction of damage. The ability to predict the damage
modes, damage path and the failure loads of statically
loaded center notch tensile specimens has been success-
fully demonstrated. Continuum damage model has been
extended to the analysis of rotor blade for investigation of
damage behavior and complex state of stress. Experimental
investigations are mandatory to verify the accuracy,
repeatability and reliability of predicted behavior. Opti-
Fig. 13 Normal Stress in matrix direction (s22)
mization studies are indispensable to arrive at a
competitive design especially for aerospace applications.

Data Availability Statement (DAS) The datasets generated during

and/or analyzed during the current study are available from the cor-
responding author on reasonable request.

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