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Title: Verification and validation of residual stresses in composite structures

Process-induced residual stresses occur in composite structures composed of dissimilar materials. As these residual stresses could result in fracture, their consideration when designing composite parts is necessary. However, the experimental determination of residual stresses in prototype parts can be time and cost prohibitive. Alternatively, it is possible for computational tools to predict potential residual stresses. Therefore, the objectives of the presented work are to demonstrate an efficient method for simulating residual stresses in composite parts, as well as the potential value of statistical methods during analyses for which material properties are unknown. Specifically, a simplified residual stress modeling approach is implemented within Sandia National Laboratories’ SIERRA/SolidMechanics code. Concurrent with the model development, bi-material composite structures are designed and manufactured to exhibit significant residual stresses. Then, the presented modeling approach is rigorously verified and validated through simulations of the bi-material composite structures’ manufacturing processes, including a mesh convergence study, sensitivity analysis, and uncertainty quantification. The simulations’ final results show adequate agreement with the experimental measurements, indicating the validity of a simple modeling approach, as well as a necessity for the inclusion of material parameter uncertainty in the final residual stress predictions.
Authors:
 [1] ;  [1] ;  [1] ;  [1]
  1. Sandia National Lab. (SNL-CA), Livermore, CA (United States)
Publication Date:
Report Number(s):
SAND-2017-7846J
Journal ID: ISSN 0263-8223; 655648
Grant/Contract Number:
AC04-94AL85000
Type:
Accepted Manuscript
Journal Name:
Composite Structures
Additional Journal Information:
Journal Volume: 194; Journal Issue: C; Journal ID: ISSN 0263-8223
Publisher:
Elsevier
Research Org:
Sandia National Lab. (SNL-NM), Albuquerque, NM (United States)
Sponsoring Org:
USDOE National Nuclear Security Administration (NNSA)
Country of Publication:
United States
Language:
English
Subject:
42 ENGINEERING; Computational modeling; Finite element analysis (FEA); Statistical properties/methods
OSTI Identifier:
1478330

Nelson, Stacy Michelle, Hanson, Alexander Anthony, Briggs, Timothy, and Werner, Brian T. Verification and validation of residual stresses in composite structures. United States: N. p., Web. doi:10.1016/j.compstruct.2018.04.017.
Nelson, Stacy Michelle, Hanson, Alexander Anthony, Briggs, Timothy, & Werner, Brian T. Verification and validation of residual stresses in composite structures. United States. doi:10.1016/j.compstruct.2018.04.017.
Nelson, Stacy Michelle, Hanson, Alexander Anthony, Briggs, Timothy, and Werner, Brian T. 2018. "Verification and validation of residual stresses in composite structures". United States. doi:10.1016/j.compstruct.2018.04.017. https://www.osti.gov/servlets/purl/1478330.
@article{osti_1478330,
title = {Verification and validation of residual stresses in composite structures},
author = {Nelson, Stacy Michelle and Hanson, Alexander Anthony and Briggs, Timothy and Werner, Brian T.},
abstractNote = {Process-induced residual stresses occur in composite structures composed of dissimilar materials. As these residual stresses could result in fracture, their consideration when designing composite parts is necessary. However, the experimental determination of residual stresses in prototype parts can be time and cost prohibitive. Alternatively, it is possible for computational tools to predict potential residual stresses. Therefore, the objectives of the presented work are to demonstrate an efficient method for simulating residual stresses in composite parts, as well as the potential value of statistical methods during analyses for which material properties are unknown. Specifically, a simplified residual stress modeling approach is implemented within Sandia National Laboratories’ SIERRA/SolidMechanics code. Concurrent with the model development, bi-material composite structures are designed and manufactured to exhibit significant residual stresses. Then, the presented modeling approach is rigorously verified and validated through simulations of the bi-material composite structures’ manufacturing processes, including a mesh convergence study, sensitivity analysis, and uncertainty quantification. The simulations’ final results show adequate agreement with the experimental measurements, indicating the validity of a simple modeling approach, as well as a necessity for the inclusion of material parameter uncertainty in the final residual stress predictions.},
doi = {10.1016/j.compstruct.2018.04.017},
journal = {Composite Structures},
number = C,
volume = 194,
place = {United States},
year = {2018},
month = {4}
}