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Composite Structures :
Design Issues and Practices

Topics to be covered
Laminated Construction: Choice of Lay-up,
practical considerations; Design aids, Carpet Plots.
Failure modes in Composites; Sub-critical and
Critical Modes; Tension, Compression, Shear;
Notch sensitivity; Fatigue; Impact damage; Effect of
Environment;
Designing with composites Material Design
allowables, Catering for Environmental effect and
Scatter; A Basis, B basis; Hot-wet); Design against
Impact; Design for delamination growth

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Todays Lecture
Outline

Laminated Construction
Choice of Lay-up, practical considerations
Design aids: Carpet Plots

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Laminated Composites

A Unidirectional Layer
(Lamina, Ply)
Another UD Layer

Different Fiber Orientation

A Bi-directional Layer
Another BD Layer

Different Fiber Orientation

Laminate:

- plies of different orientations


stacked together
Prakash Mangalgiri

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Choice of lay-up
Fibre orientations

Stacking sequence

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What Lay-ups to use?

Theoretically all angular orientations can be used;


but, practical considerations put a limit
Data generation would be a huge task

Orientations limited to 0, +45, -45 and 90 deg.

In special cases, other angles (30, 60 etc) may be used

Stacking Sequence

Generally limited to symmetric


Unsymmetric lay-up causes warping in fabrication
(Also, other effects, e.g, loss of stiffness)
Newer techniques - compensating for warping by
tool-shaping - yet to be proved; No acceptance.
Minimum 10% plies in each direction

Optimisation: may be limited to choice of 0 deg


ref and thicknesses of 0, +45, -45 and 90 deg plies

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Laminated Composite Deformation

Peculiar Coupled Deformation Behaviour:

Extension-Shear

Bending-Shear

Extension- Torsion

Bending-Stretch

Balanced :
n( ) n( )

Symmetric :
( h) ( h)

Bending-Stretch
& Twist - Shear

Laminate Theory can tell us which stacking sequences will


have what kind of coupling
Balanced Symmetric Laminates will avoid coupling

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Composite behavior

A16, A26 :
Normal-Shear
coupling

Nx
N
y
N xy

M x
M y

M xy

A11
A
12
A16
= B
11
B
12
B16

B : Extension
(Stretching)-Bending
coupling

A12

A16

B11

A22 A26

B12

A26 A66

B16

B12

B16

D11

B22 B26

D12

B26 B66

D16

D16, D26 :
BendingTwisting
coupling

B12 B16
B22 B26
B26 B66

D12 D16
D22 D26

D26 D66

x0
0
y
0
xy

x

y
xy

Coupling can be avoided by proper choice


of ply angles and stacking sequence

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Bending-Stretching Coupling

66

66

Asymmetric
Cross-ply
Lay-up.

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Extension-Torsion & Bending-Shear Coupling
6

66

16

26

6
6

66

AntiSymmetric
Lay-up.
Balanced

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Normal-Shear & Bending-Torsion Coupling
6
6

16

26

66

16

66

Symmetric
Lay-up.
But not
balanced

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Only Bending-Torsion Coupling

66

16

26

16

26

66

Symmetric
Lay-up.
Balanced

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No Coupling!

66

66

Symmetric
Cross-ply
Lay-up.
Balanced

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Lay-ups : Industry Practice

Avoid unsymmetric laminates

Warping in fabrication, loss of effective stiffness, lower


buckling load, lower frequency of vibration
B=0 for symmetric laminates. Simpler analyses.

If No Coupling is desired

Only cross-ply (i.e., 0/90 plies) balanced symmetric


laminates. Too much of a limitation!

Use balanced symmetric 0/45/-45/90 family

Bending-twisting coupling (D16, D26 0). Not very severe,


particularly if proportion of 45 plies is limited

Unbalanced (but symmetric) laminates also acceptable

In any case, the analysis is done for all the lamina stresses
and the failure criterion caters to shear failure. So, normalshear coupling is not of much consequence

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Free edge

Interlaminar stresses
and delamination

90

Mismatch of Cross Couplings,


i.e. Poisson Ratios and
Normal-Shear Coupling Coeff

Robert M. Jones, Delamination-Suppresion Concepts for


Composite Laminate Free Edges, Moscow International
Composites Conference, 1990 (MICC 90) pp 132-146

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Lay-ups : Further considerations

Free edge effects such as large interlaminar


stress or delamination should be avoided
If angle-ply laminates are used, the layers with
+ and - orientations should be alternated
instead of bunching
E.g., [+/-/ +/-]s instead of [+/+/- /-]s

However, if a laminate contains 0, 90, and


layers, adjacent and - layers should be
interspersed with 0 or 90 layers.

E.g., [45/0/90/-45]S is better than [90/+45/-45/0]S


or [0/+45/-45/90]S

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Stress

Brittle Behaviour; Stress Concentration


0

45

SCF

Strain

10

Hole in Orthotropic Plate

SCF-A
SCF-B

6
4
2

E1/E2

-2

10

15

20

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Lay-ups : Still further considerations

High SCF.

Low
ductility

Low
Strength;
Low
efficiency

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% of 90 plies
plies

Lay-ups: Still further


Considerations

0 plies
of 0
%
% of
plies

To be avoided, particularly for high fastener


loads
Expanded region for lightly
loaded structure

Recommended for highly


loaded structures
Quasi Isotropic
Point

LCA Usage

% of 45 plies

Paolo Feraboli, JOURNAL OF AIRCRAFT, Vol. 46, No. 4, JulyAugust 2009

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Lay-up Best Practices

Recommended Practice
Try to employ Balance and
Symmetry whenever possible

Reason
Minimizes value of B-matrix,
avoiding bending, coupling,
warping and twisting effects
Add fabric ply to inner or outer
Fabric ply can absorb more impact
layer
damage as well as minimize
drilling breakout for holes
Add 45 plies with at least one
Increases buckling for thin
pair on laminate extremes (except laminates as well as better
for specific designs where bending damage tolerance
loads require 0 or 90 outer plies)
Use larger fraction of +/- plies in
Shear loads are best handled with
shear regions
additional +/- plies in a structure
Adapted from : Beckwith, SW, Designing with Composites: Suggested Best Practices Rules,
SAMPE J, 45(1), p.16-17 , 2009. http://www.sampe.org/Other/TechTidbitsJanFeb09.pdf

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Lay-up Best Practices

Recommended Practice
Use 0/90/45 laminate with
minimum of one layer in each
direction (Min 10% : LCA rule)
A +45 and -45 ply are in contact
with each other ??
45 layers are added in pairs (45)

Reason
0 layers for longitudinal loads
90 layers for transverse loads
45 layers for shear loads
Minimizes interlaminar shear

In-plane shear is carried in tension


and compression in the 45 layers
Composites are elastic to failure

Minimize stress concentrations.


Not more than 50% plies in any dir.
Achieve a balance between the following:
Maintain a homogeneous stacking Increased strength achieved
sequence by banding several plies
of the same orientation together
Avoid stacking too many plies all at Delamination and residual stresses
one angle
more likely if not avoided

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Carpet Plots

Here is an example

[% of 90 plies = 100 (% of 45 plies) (% of 0 plie)]

From : PK Mallik, Fiber Reinforced Composites, 3rd Ed, CRC Press. Chapter 6.

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Carpet plot

Visualisation of a property for a whole family of


0/90/45 laminates
Kind of Design aid as a property chart. A ReadyReckoner
Normally laminate property is derived from lamina
property by theoretical calculations
Constitutive relations
Laminate Plate theory

Does not account for stacking sequence

Generally ok for Balanced Symmetric Laminates


No Couplings

Validation of the theoretical calculations done by tests


on laminate specimen at selected points of interest

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Carpet plot : Allowable tensile strength

From : PK Mallik, Fiber Reinforced Composites, 3rd Ed, CRC Press. Chapter 6.

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One commercial example

http://www.ascgenoa.com/datasheets/CARPET_PLOT.jsp

GENOA

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Some thumb rules

Hartsmiths 10% Rule (for 0/45/90 family)

For tensile strength or modulus in any fibre direction:


o plies in that direction contribute 100%
o plies in other directions contribute 10%
(of the property in respective fibre direction)
Thus, E0 = EL [1 x p0 + 0.1 x (1-p0)] = EL[0.1+0.9p0], etc
E.g.,
For [50/20/20/10] laminate,
E0 = [0.1+ 0.9x0.5] EL or 0.55EL
E45 = [0.1+0.9x0.4] EL or 0.46EL
E90 = [0.1+0.9x0.1] EL or 0.19EL

Approximate Formula for Poisson Ratio:


45 + 0.4
12 =
45 + 3.690 + 0.4

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10% Rule vs LPT Calculation

https://www.google.co.in/search?q=HArtSmith+formula+for+Composite+strength&source=lnms&tbm=isch&sa=X&ved=0ahUKEwjUhKaH3rfLAhWLwY4KHQlnAK0Q_AUIBygB&biw=1280&bih=557#tbm=isch
&q=HArt-Smith+10%25+rule+for+Composite+strength&imgrc=00zF4Rd4wCfA8M%3A

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Carpet Plots for
Poisson Ratio
Hartsmith
thumb rule
vs

CLPT

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Questions?

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