Scribd Logo
Upload

Welcome to Scribd!

  • 16 views

    Seminar

    Uploaded by

    Jyothishkumar M
    The document summarizes research on modeling the deformation and fracture of thermoplastic weld joints using cohesive zone modeling. It describes conducting experiments on single lap shear joints of carbon fiber reinforced thermoplastic composites welded using ultrasonic welding. The experiments are used to validate a finite element model using cohesive zone modeling and Hashin damage criteria to model failure in the weld and composite materials. The model is able to predict the load-displacement response but does not fully capture the failure modes observed in experiments due to only modeling the weld and not the composite adherends.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd

    Seminar

    Uploaded by

    Jyothishkumar M
    16 views24 pages
    The document summarizes research on modeling the deformation and fracture of thermoplastic weld joints using cohesive zone modeling. It describes conducting experiments on single lap shear joints of carbon fiber reinforced thermoplastic composites welded using ultrasonic welding. The experiments are used to validate a finite element model using cohesive zone modeling and Hashin damage criteria to model failure in the weld and composite materials. The model is able to predict the load-displacement response but does not fully capture the failure modes observed in experiments due to only modeling the weld and not the composite adherends.

    Copyright

    © © All Rights Reserved

    Available Formats

    PPTX, PDF, TXT or read online from Scribd

    Did you find this document useful?

    Is this content inappropriate?

    The document summarizes research on modeling the deformation and fracture of thermoplastic weld joints using cohesive zone modeling. It describes conducting experiments on single lap shear joints of carbon fiber reinforced thermoplastic composites welded using ultrasonic welding. The experiments are used to validate a finite element model using cohesive zone modeling and Hashin damage criteria to model failure in the weld and composite materials. The model is able to predict the load-displacement response but does not fully capture the failure modes observed in experiments due to only modeling the weld and not the composite adherends.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    16 views24 pages

    Seminar

    Uploaded by

    Jyothishkumar M
    The document summarizes research on modeling the deformation and fracture of thermoplastic weld joints using cohesive zone modeling. It describes conducting experiments on single lap shear joints of carbon fiber reinforced thermoplastic composites welded using ultrasonic welding. The experiments are used to validate a finite element model using cohesive zone modeling and Hashin damage criteria to model failure in the weld and composite materials. The model is able to predict the load-displacement response but does not fully capture the failure modes observed in experiments due to only modeling the weld and not the composite adherends.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    of 24

    COHESIVE ZONE MODELLING OF THE

    DEFORMATION  AND FRACTURE OF


    THERMOPLASTIC WELD JOINT

    Prepared by
    Guided by BINOY SATHYADAS
    Prof. ARUN B.S S3 Machine Design, Roll no:8
    Assistant Professor in mechanical engineering
    College Of Engineering Trivandrum

    1
    Department of Mechanical Engineering
    CONTENTS

     Introduction
     Literature Review
     Experimental Procedure
     Numerical Simulation
     Results
     Conclusions
     Reference

    2
    INTRODUCTION

    Thermoplastic Composites
     Synthetic plastics that can be melted, shaped and cooled to form
    specific design shapes.
     Polyethylene, polypropylene, polyvinyl chloride, polystyrene etc
    Thermoplastic Welding
     Complex, intricate joints with molecular bonds are more reliable and
    effective than fastening or adhesive bonding.
     Common welding techniques are friction welding, ultrasonic welding,
    induction welding, gas welding and laser welding.
    3
    INTRODUCTION-CONTINUED

    Cohesive Zone Modelling


     Numerical Modelling of joints is an efficient
    and cost saving approach for mechanical
    evaluation of welds
     CZM can be used to predict the damage
    initiation and crack propagation.
     Traction separation Law uses parameters
    such as the energy required to create new
    surfaces.
    Fig 1: Traction separation Law
     Disadvantage of CZM –Crack path and
    strength in different modes have to be known.
    4
    LITERATURE REVIEW

    [1] Q.Zhao et.al (2022)


     Developed finite element model to analyse mechanical behavior of
    TPC joint assembled by ultrasonic welding
     The results from FEA was validated using experimental data
     Results from cohesive zone modelling was used to optimize the weld
    parameters
    [2] T.Zhao et.al (2019)
     Experimental evaluation of strength of ultrasonic weld on TPC and
    comparison with that of mechanical fasteners
     Load displacement behaviour and out of plane displacement was
    measured
    5
    LITERATURE REVIEW-CONTINUED

    [3] M.N.Cavalli et.al (2005)


     Cohesive zone model of ultrasonic weld in Aluminium sheet was
    developed to study deformation and fracture of weld joints.
     Failure mechanism of ultrasonic weld spot was explained.

    6
    EXPERIMENTAL PROCEDURE

    Model Preparation & Testing


     Carbon Fibre – fibre and Polyphenylene Sulphide – matrix
     Six Plies
     [0/90⁰]3s stacking sequence
     Hot-press at 320℃ and 1MPa for 20 mins
     Welded using 20KHz Rinco Dynamic microprocessor-controlled
    ultrasonic welder with max power output of 3000 W

    7
    EXPERIMENT-CONTINUED

     Single lap joint was mechanical


    tested using Zwick/Roell 250kN
    UTM
     Out of Plane displacement of
    joint was measured using 2 CCD
    Fig 2:Single lap shear joint specimen
    cameras combined with vic-3D
    data image correlation system

    Fig 3: Joint with out of plane displacement

    8
    EXPERIMENT-CONTINUED

    Figure 4: Mechanical test setup


    (1)specimen(2)hydraulic grips(3)CCD
    cameras

    9
    EXPERIMENT-CONTINUED

    Table 1: Material properties of the 5HS woven fabric T300 CF/PPS thermoplastic composite

    E11(GPa) E22(GPa) G12(GPa) G13(GPa) G23(GPa) Xt(MPa) Xc(MPa)

    55.8 53.8 4.04 44.8 60 757 643


    Yt(MPa) Yc(MPa) S12(MPa) S13(MPa) S23(MPa) ρ(g/cm3) ν12 ν23

    754 637 119 831 1027 1.55 0.31 0.33


    Eij and Gij represents elastic moduli
    Xt, Xc are tensile and compressive strengths in longitudinal direction
    Yt, Yc are tensile and compressive strength in transverse direction
    S12 ,S13 ,S23 are the in-plane and out-of-plane shear strengths

    10
    EXPERIMENT-CONTINUED

    Failure Modes
     Fibre Matrix Debonding : Bare fibres or deep fibre imprints at welded
    zone.
     Fibre Cracking : composite failure of adherends by fibre breaking
     Matrix Cracking : composite failure of adherends by matrix rupture

    11
    NUMERICAL SIMULATION

    Damage Model of Welded Joint


     Major failure mechanism of thermoplastic welded joint is fibre matrix
    debonding
     Cohesive Zone Model is used to model the weld
     Bilinear traction separation law is used

    12
    NUMERICAL SIMULATION-CONTINUED

     Cohesive zone is characterised


    by slope, maximum stress and
    area under traction separation
    curve
     Quadratic traction initiation
    criteria is given by

    =1
    Figure 5: Bilinear traction-separation law in CZM

    13
    NUMERICAL SIMULATION-CONTINUED

     For crack propagation, Benzeggagh-Kenane(BK) mixed


    mode failure criterion is adopted
     It is expressed as

    Where, , , are fracture energies in normal and shear modes of failure


    (areas under traction-displacement curves)

    14
    NUMERICAL SIMULATION-CONTINUED

    Damage Model for TPC Adherends


    Composite material failure is accounted by Hashin Damage Criterion
    Four typical failure indexes in composite materials are
    (1) Fibre breakage in tension
    +
    (2) Fibre breakage in compression

    Where Xt, Xc are tensile and compressive strengths in longitudinal


    direction

    15
    NUMERICAL SIMULATION-CONTINUED

    (3) Matrix damage in tension

    (4) Fibre breakage in compression

    Where Yt, Yc are tensile and compressive strength in transverse direction and S12 ,S13 ,S23
    are the in-plane and out-of-plane shear strengths

    16
    NUMERICAL SIMULATION-CONTINUED

    The cohesive parameter were directly adopted as the material properties of the utilized
    PPS resin as summarized in table 2.

    Table 2: Material Properties of Cohesive Zone


    Initial Stiffness(MPa) Interfacial Strength(MPa) Fracture Toughness(N/mm)
    K0n K0s=K0t σ 0n τ0s=τ0t Gcn Gcs=Gct
    3800 3725 90.3 125 0.199 0.65

    17
    RESULTS

     Figure 6 shows the comparison between the numerical and


    experimental results regarding the Load displacement and out of
    plane displacement
     Simulation results were similar to that of mechanical test results

    18
    Figure 6: Comparison of L-D and OPD response between numerical and experimental results
    RESULTS-CONTINUED

     Figure 6 shows comparison of failure mechanisms of TPC welded


    joints obtained from FE model and experiment

    (a) Damage of cohesive zone elements (b) Experimental observation of


    based on quadratic traction separation ultrasonic spot welded joint
    criterion
    19
    Figure 7: Failure of joint by Numerical and Experimental method
    RESULTS-CONTINUED

    (c) Fibre tensile damage (d) Fibre compressive damage

    (e) Matrix tensile damage (f) Matrix compressive damage

    Figure 8: Damage of adherends based on Hashin damage criterion


    RESULTS-CONTINUED

     In Numerical simulation failure occurs in the welded zone only.


    But in experiment TPC adherends also failed
     This mismatch is because spot weld was entirely modelled with
    properties of thermoplastic resin

    21
    CONCLUSIONS

     Cohesive Zone Modelling can be used to investigate the mechanical


    behaviour of ultrasonic welded single lap joints in thermoplastic
    composites
     CZM results was validated by results from experiment
     Mechanical behavior was almost same but failure modes was not
    completely consistent
     CZM cannot be readily used to predict failure. Proper understanding
    of the failure modes and material properties is needed to predict failure
    in weld on similar material.

    22
    REFERENCES

    1) Q.Zhao, H.Wu, X.Chen, Y.Ni, X.An, W.Wu, T.Zhao; Insight into the
    structural design strategies of multi-spot ultrasonic welded joints in
    thermoplastic composites: finite element analysis (2022); composite
    structures 299
    2) T.Zhao, C.Rans, I.F.Villegas, R.Benedictus; On sequential Ultrasonic spot
    welding as an alternative to mechanical fastening in thermoplastic composite
    assemblies: A study of single column multi-row single lap shear joints (2019);
    composites part A 120
    3) M.N.Cavalli,M.D.Thouless,Q.D.Yang; Cohesive Zone modelling of the
    deformation and fracture of spot welded joints (2005); Fatigue fracture
    Engineering Material Structures 28;page 861-874
    4) T.Zhao, Q.Zhao, W.Wu, L.Xu, Y.Li, Z.Wan, I.F.Villegas, R.Benedictus;
    Enhancing weld attributes in Ultrasonic spot welding of carbon fibre-
    reinforced composites: effect of sonotrode configuration and process control 23
    (2021); composites Part B 211
    THANK YOU

    You might also like

    pFad - Phonifier reborn

    Pfad - The Proxy pFad of © 2024 Garber Painting. All rights reserved.

    Note: This service is not intended for secure transactions such as banking, social media, email, or purchasing. Use at your own risk. We assume no liability whatsoever for broken pages.


    Alternative Proxies:

    Alternative Proxy

    pFad Proxy

    pFad v3 Proxy

    pFad v4 Proxy