Abstract
In contrast to homogenous materials, composite materials can be customized to achieve desirable strength-to-weight ratios, corrosion prevention, and fatigue resistances. However, the heterogeneity in composite materials brings the challenges in design, production, characterization, and testing. Trial and error practices and numerous experiments are usually required to deal with the uncertainties of composite material properties. Mathematical modeling or numerical simulations have been studied to shorten product development cycles. In this paper, we use finite element analysis (FEA) approach to diagnose the fatigue failure of composite materials. The proposed approach is novel in sense that (1) the new procedure and guideline has been developed for defining fluctuated loads in actual applications, (2) the motion simulation is conducted to characterize dynamic loads, (3) FEA is suggested as a diagnosis tool to detect design defects when failure occurs; and (4) conventional Minor’s rule is expended to evaluate the fatigue life of machine elements with the consideration of both the variations of magnitudes and frequencies of stresses. A case study is provided to illustrate the analysis of the fatigue failure of products. A comparison of simulation and experimental results has verified the effectiveness of the developed approaches.
Article PDF
Similar content being viewed by others
Avoid common mistakes on your manuscript.
References
Bi ZM (2011) Revisit system architecture for sustainable manufacturing. J Sustain 3(9):1323–1340
Bi ZM (2011) Design and simulation of dust extraction for composite drilling. Int J Adv Manuf Technol 54(5–8):629–638
Bi ZM, Kang B (2014) Sensing and responding to the changes of geometric surfaces in flexible manufacturing and assembly. Enterp Inform Syst 8(2):225–245
Bi ZM, Wang L (2012) Energy modeling of machine tool for optimization of machine setup. IEEE Trans Autom Sci Eng 9(3):607–613
Bi, Z. M., and Wang, L., (2013). Chapter 5: Manufacturing Paradigm Shift towards Better Sustainability, in Cloud Manufacturing, Springer-Verlag London, ISBN: 978-1-4471-4934-7, doi: 10.1007/978-1-4471-4935-4_5
Bi ZM, Gruver WA, Zhang WJ, Lang SYT (2006) Automated modeling of modular robotic configurations. Robot Auton Syst 54:1015–1025
Bi ZM, Lang SYT, Shen WM (2008) Reconfigurable manufacturing systems: the state of the art. Int J Prod Res 46(4):967–992
Bi, Z. M., Hinds, B., Jin, Y., Gibson, R., and McToal, P. (2009). Drilling Processes of Composites-The State of the Art,” in Drilling of Composite Materials, Nova Science Publisher, ISBN: 978-1-60741-163-5, pp.137-171.
Bi ZM, Xu LD, Wang C (2014) Internet of things for enterprise systems of modern manufacturing. IEEE Trans Ind Inform 10(2):1537–1546
Bi ZM, Pomalaza-Raez C, Singh Z, Nicolette-Baker A, Pettit B, Heckley C (2014) Reconfiguring machines to achieve system adaptability and sustainability: a practical case study. Proc Inst Mech Eng Part B-J Eng Manuf 228:1676–1688
Budynas, R., Nisbett, J. K. (2013) Shigley’s Mechanical Engineering Design, 9th Edition, ISBN: 978-0-07-352928-8, McGraw Hill
Degrieck J, van Paepegem W (2001) Fatigue damage modeling of fibre-reinforced composite materials: review. Appl Mech Rev 54(4):279–300
Ferguson, C., (2014) Historical Introduction to the Development of Material Science and Engineering as a Teaching Discipline. http://www.materials.ac.uk/pub/materials-history-intro.pdf
Firehole Composites (2010) Fatigue Life Prediction in Composite Materials, http://www.firehole.com/documents/WP_Fatigue-Life-Prediction-in-Composite-Materials.pdf
Gupta KK, Meek JL (1996) A brief history of the beginning of the finite element method. Int J Numer Methods Eng 39:3761–3774
Hossain ME (2011) The current and future trends of composite materials: an experimental study. J Compos Mater 45(20):2133–2144
Liu Y, Mahadevan S (2005) Probabilistic fatigue life prediction of multidirectional composite laminates. Compos Struct 69:11–19
Loftas AAG (1966) Advances in materials science. University of London Press, London
Mandell, J. F., Samborsky, D. D., Combs, D. W., Scott, M. E., Cairns, D. S. (1998) Fatigue of Composite Material Beam Elements Representative of Wind Turbine Blade Substructure, National Renewable Energy Laboratory, Report for Contract No. DE-AC36-83CH10093 1998, www.abdmatrix.com/phcdl/upload/fatigue/Fatigue%20of%20Composite%20Material%20Beam%20Elements%20Representative%20of%20Wind%20Turbine%20Blade%20Substructures.pdf
Mandell, J. F., Samborsky, D. D., Agastra, P. (2008). “Composite Materials Fatigue Issues in Wind Turbine Blade Construction”, www.coe.montana.edu/composites/documents/SAMPE%202008.pdf
Mandell, J. F., Samborsky, D. D., Wahl, N. K., Sutherland, H. J. (2014) Testing and Analysis of Low Cost Composite Materials under Spectrum Loading and High Cycle Fatigue Conditions, http://windpower.sandia.gov/other/ICCM14_Mandell_Testing.pdf
Mao H, Mahadevan S (2002) Fatigue damage modelling of composite materials. Compos Struct 58(4):405–410
Mathur, S., Gope, P. C., Sharma, J. K. (2007). Prediction of Fatigue Lives of Composite Material by Artificial Neural Network, Proceedings of the SEM 2007 Annual Conference and Exposition, Springfield, Massachusetts, USA, June 4–6, 2007, Copyright Society for Experimental Mechanics, Inc., Bethel, CT USA
National Aeronautics and Space Administration (NASA) (2010). Draft Materials, Structures, Mechanical Systems, and Manufacturing Roadmap Technology Area 12, http://www.nasa.gov/pdf/501625main_TA12-MSMSM-DRAFT-Nov2010-A.pdf
National Institute of Standards and Technology (NIST) (2009). Manufacturing: Accelerating the Incorporation of Materials Advances into Manufacturing Processes, Technology Innovation Program, NIST, Gaithersburg, MD, U.S.A., http://www.nist.gov/tip/prev_competitions/upload/manuf_wp_032009.pdf
O’ Brien-Bernini, F. (2011) Composites and Sustainability – When Green Becomes Golden, http://www.reinforcedplastics.com/view/21728/composites-and-sustainability-when-green-becomes-golden/
Performance Composites (2014) Material Properties for Carbon Fibers, http://www.performance-composites.com/carbonfibre/mechanicalproperties_2.asp
Romaniw, Y., Bras, B. (2012) Survey on Common Practices in Sustainable Aerospace Manufacturing for the Purpose of Driving Future Research, 19th CIRP International Conference on Life Cycle Engineering, Berkeley, 2012 http://www.manufacturing.gatech.edu/sites/default/files/uploads/pdf/214_Bras.pdf
Smith, F. (2013) The Use of Composites in Aerospace: Past, Present, and Future Challenges, http://avaloncsl.files.wordpress.com/2013/01/avalon-the-use-of-composites-in-aerospace-s.pdf
Sutherland, H. J., Mandell, J. F. (2004). “Updated Goodman Diagrams for Fiberglass Composite Materials Using the DOE/MSU Fatigue Database”, windpower.sandia.gov/other/Global04_18983_Sutherland_Final.pdf
Tomblin, J. (2008) Overview of Composite Material trends in Aviation Manufacturing, Wichita State University, http://webfiles.wichita.edu/cedbr/WIRED_comp_ov_5_14_08.pdf
Torquato S (2000) Modeling of physical properties of composite materials. Int J Solids Struct 37:411–422
Verpoest, I. (2014) Composite Materials: Trends and Challenges, https://dspace.ndlr.ie/bitstream/10633/31976/1/PMC_2.pdf
Witten, E., John, B. (2013) Composites Market Report 2013: Market Developments, trends, Challenges and Opportunities, http://www.pultruders.com/files/pultruders.com/Documents/market_report_2013.pdf
Wrobel G, Kaczmarczyk J, Stabik J, Rojek M (2009) Numerical models of polymeric composite to simulate fatigue and ageing processes. J Achiev Mater Manuf Eng 34(1):31–38
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Bi, Z.M., Mueller, D.W. Finite element analysis for diagnosis of fatigue failure of composite materials in product development. Int J Adv Manuf Technol 87, 2245–2257 (2016). https://doi.org/10.1007/s00170-016-8619-z
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-016-8619-z