Publications Details

Uncertainty quantification of simulated residual stresses in multi-material composite structures

Hanson, Alexander A.; Nelson, Stacy M.; Werner, Brian T.; Briggs, Timothy B.

Multi-material composite structures develop residual stresses during the curing process due to dissimilar material properties, which eventually may lead to failure in the form of fracture, delamination, or disbonding. Experimentally determining residual stresses can be both time and cost prohibitive, whereas accurate simulated predictions of residual stresses can be cheaper and provide equivalent information during the design process. Residual stresses can be simulated through several different approaches of varying complexity. The method employed in this study assumes the majority of residual stresses are developed due the mismatch of coefficients of thermal expansion and polymer shrinkage, which is indirectly accounted for by calibrating the simulation with an experimentally determined stress free temperature. This method has shown success in predicting the residual stress states across different material combinations and structures in previous studies. Simply using single, or nominal, inputs to the simulation may provide a reasonable prediction, but will be unable to provide any confidence when failure could occur. Therefore, one must consider the natural stochastic behavior of the materials and geometry through an uncertainty quantification study. However, a limitation in performing uncertainty quantification studies for more complex models exists due to the large number of material and geometry parameters that need to be considered. The results from a previously conducted survey of sensitivity analysis methods were leveraged to reduce the number of parameters considered during an uncertainty quantification study, as well as decrease the computational cost in determining the sensitive parameters. This allowed the application of uncertainty quantification methods to validate more complex multi-material structures against experimental results. The structure that will be considered is a multi-material split ring comprised of three layers: Aluminum, glass fiber composite, and carbon fiber composite.