Cohesive Finite Element Model Research Articles

FE-based machine learning model for predictive damage assessment in bonded composite joints via acoustic emission

This study systematically evaluated the mechanical performance of bonded composite single-lap joints with varying overlap lengths under tensile load. By integrating Acoustic Emission (AE) signals with Finite Element (FE) modeling, this study established a predictive machine learning model to enhance the understanding and prediction of failure mechanisms. Firstly, AE signal features were extracted and utilized as inputs for a hierarchical clustering model to classify AE signals into matrix cracking, fiber breakage, and adhesive debonding. AE signals classified as adhesive debonding were further analyzed by accumulating counts, amplitude, and energy. A cohesive zone-based Finite Element (FE) model was developed to simulate progressive debonding damage in the adhesive layer. After calibration with experimental results, various physical quantities such as stress, the damage initiation indicator, and the stiffness degradation indicator were extracted for correlation analysis. The experiments and simulations unravel the missing relationship between the AE and FE data. A strong correlation was observed between the cumulative count and cumulative amplitude with the damage initiation indicator, and between cumulative energy with the damage propagation indicator. Finally, based on the disclosed relationship between AE and FE data, a Support Vector Regression (SVR) model was established to predict the damage indicator. The developed model accurately predicted testing datasets within low absolute error ranges, underscoring its high predictive accuracy. Comprehensive stress analysis proposed a quantitative damage initiation indicator of 0.32 for structural fractures and a damage indicator of 0.12 for allowable stress levels. Consequently, combining AE techniques with FE modeling provided an effective tool for evaluating damage evolution in bonded composite joints.

Investigation of Delamination Characteristics in 3D-Printed Hybrid Curved Composite Beams.

This study focuses on understanding the impact of different material compositions and printing parameters on the structural integrity of hybrid curved composite beams. Using the continuous filament fabrication technique, which is an advanced fused deposition modelling process, composite curved beams made of short carbon and various continuous fibre-reinforced nylon laminae were fabricated and subjected to four-point bending tests to assess their delamination characteristics. The results show that the presence of five flat zones in the curved region of a curved beam achieves 10% and 6% increases in maximum load and delamination strength, respectively, against a smooth curved region. The delamination response of a curved composite beam design consisting of unidirectional carbon/nylon laminae is superior to that of a curved beam made of glass fibre/nylon laminae, while the existence of highly strengthened glass fibre bundles is alternatively quite competitive. Doubling the number of continuous fibre-reinforced laminae results in an increase of up to 36% in strength by achieving a total increase in the beam thickness of 50%, although increases in mass and material cost are serious concerns. The hybrid curved beam design has a decrease in the maximum load and the strength by 11% and 13%, respectively, when compared with a non-hybrid design, which consists of some type of stronger and stiffer nylon laminae instead of short carbon fibre-reinforced conventional nylon laminae. Two-dimensional surface-based cohesive finite element models, which have a good agreement with experimental results, were also established for searching for the availability of useful virtual testing. The results from this study will greatly contribute to the design and numerical modelling of additively manufactured hybrid composite curved beams, brackets, and fittings.

A Machine Learning Boosted Data Reduction Methodology for Translaminar Fracture of Structural Composites

AbstractThis work explored a machine learning (ML) algorithm as a fast data reduction method for translaminar fracture energy in composite laminates. The method was validated with translaminar fracture tests on compact tension (CT) specimens on AS4/8552 and IM7/8552 cross-ply lay-ups. Experimental fracture energy and R-curves for both materials were determined using the most common data reduction methods, such as the compliance calibration (CC), the area (AM) and the Irwin relationship (IM). Our new data reduction method uses a surrogate model based on an artificial neural network (ANN) trained with synthetic data generated with the cohesive crack finite element model. Such a surrogate model maps the cohesive properties with the corresponding load–displacement, crack-displacement and energy-displacement curves with interrogation times in the order of 20 ms and relative errors in the load–displacement and crack growth less than 2%. Such performance enabled its encapsulation to approximate the inverse problem to infer the cohesive parameters with the maximum likelihood estimator (MLE) directly from the experimental load–displacement and crack-displacement curves. The results demonstrated the ability of the model to deliver cohesive parameter inference directly from the macroscopic tests carried out at the laboratory level.

Incorporation of compaction effects in the automated generation of 3D woven composites representative volume elements by geometrical modelling

Advanced 3D woven composites have become an enabling technology in many industrial applications due to their proven benefits, particularly the improvement of the out-of-plane mechanical behavior with respect to other reinforcement schemes. The latter property has been shown to be strongly affected by the effects of compaction during manufacturing. The present study proposes an automated framework, based on heuristic procedures, for the generation of representative volume elements (RVEs) of 3D woven composites, allowing to include global and local geometrical features induced by transverse compaction, such as overall thickness reduction, changes in yarn cross-sections and consistent global/local fiber fractions. The methodology is illustrated for three types of reinforcement, namely a plain weave, an angular through-thickness interlock and a 3D orthogonal RVE. The resulting geometries generated by the proposed method compare favourably with typical observations from the literature in a quantitative manner. Finally, the proposed framework is integrated with a previously developed meshing strategy to allow damage studies for a selected architecture (plain weave) under torsional loading, presenting a complete computational chain by building cohesive zone finite element models from compacted RVEs. The torque-angle response curves obtained after the damage simulations show a decrease in stiffness and an increase of damage levels with compaction, which is in line with the expectations.

In-silico simulation of nanoindentation on bone using a 2D cohesive finite element model

This study proposed and validated a 2D finite element (FE) model for conducting in-silico simulations of in-situ nanoindentation tests on mineralized collagen fibrils (MCF) and the extrafibrillar matrix (EFM) within human cortical bone. Initially, a multiscale cohesive FE model was developed by adapting a previous model of bone lamellae, encompassing both MCF and EFM. Subsequently, nanoindentation tests were simulated in-silico using this model, and the resulting predictions were compared to AFM nanoindentation test data to verify the model's accuracy. The FE model accurately predicted nanoindentation results under wet conditions, closely aligning with outcomes obtained from AFM nanoindentation tests. Specifically, it successfully mirrored the traction/separation curve, nanoindentation modulus, plastic energy dissipation, and plastic energy ratio obtained from AFM nanoindentation tests. Additionally, this in-silico model demonstrated its ability to capture alterations in nanoindentation properties caused by the removal of bound water, by considering corresponding changes in mechanical properties of the collagen phase and the interfaces among bone constituents. Notably, significant changes in the elastic modulus and plastic energy dissipation were observed in both MCF and EFM compartments of bone, consistent with observations in AFM nanoindentation tests. These findings indicate that the proposed in-silico model effectively captures the influence of ultrastructural changes on bone's mechanical properties at sub-lamellar levels. Presently, no experimental methods exist to conduct parametric studies elucidating the ultrastructural origins of bone tissue fragility. The introduction of this in-silico model presents an invaluable tool to bridge this knowledge gap in the future.

Measurement and visualization of crack patterns in basalt fabric reinforced fine-grained concrete with different textile structures using high-speed photography and a cohesive finite element model

Textile reinforced fine-grained concrete (TRC) is a new type of construction material that can be used for lightweight thin-walled structural members, sandwich thermal insulation composite panels, reinforcement of concrete structures in harsh marine environments, etc. In this paper, the tensile and flexural properties of the basalt fabric with different mesh sizes, different angles of layer, and different warp and weft densities reinforced fine-grained concrete were investigated by using a universal material testing machine through 48 experimental specimens. The crack patterns of the specimens were recorded and analyzed using high-speed photography. A cohesive finite element model was proposed to simulate the flexural properties of basalt fabric reinforced fine-grained concrete. The results showed that as the mesh sizes of basalt fabric increased, its enhancement effect on the tensile and flexural properties of fine-grained concrete weakened. The basalt fabric with a layup angle of 45° exhibited little effect during the hardening stage. Since the weft yarns were arranged along the principal stress direction of the specimens, the weft yarn density presented a great influence on the tensile and flexural properties of basalt fabric reinforced fine-grained concrete, while the effect of warp yarn density on the tensile and flexural properties of basalt fabric reinforced fine-grained concrete was not obvious. When the basalt fiber content was sufficient, the stress could be transferred in time, and the composites illustrated evident strain-hardening and multiple-cracking phenomena when subjected to tensile load. This multiple-cracking mode and the evolution mode of the cracks were recorded by high-speed photography. The finite element analysis results corresponded to the experimental results, which indicated the accuracy and applicability of the established model.

Effects of the embedding of cohesive zone model on the mesoscopic fracture behavior of Concrete: A case study of uniaxial tension and compression tests

The application of the Cohesive Zone Model (CZM) in concrete meso-mechanics solves the nonlinear problem of material crack tip well. At present, the application methods of CZM in concrete mesoscopic models include the bond mechanics characterization of the aggregate-mortar interface transition zone (ITZ) and the characterization of fracture characteristics between material micro-elements. From this, two different numerical models were derived—the combined Finite Discrete Element (FDEM) model and the Cohesive Finite Element (CFEM) model. To evaluate the difference between the two numerical models and the traditional Finite Element (FEM) model in simulating concrete mechanical behavior and crack propagation, a 3D concrete mesostructure modeling algorithm was developed in this study, including innovations in gravitational self-compacting of polyhedral aggregates. After that, the FDEM model and the CFEM model were successfully constructed based on the FEM model. Through uniaxial compression and tensile numerical simulations, it was found that the CFEM model is more in line with the theoretical and experimental mechanisms in the characterization of the static mechanical behavior and fracture process of concrete. The fracture failure angle variable defined by the CFEM model revealed that the compressed concrete material exhibited better strength and toughness due to a higher damage degree and more energy-consuming cracking mechanism. The above findings to a certain extent promote the future development of CZM in the field of concrete meso-mechanics.

Investigation of mesh dependency issues in the simulation of crack propagation in quasi‐brittle materials by using a diffuse interface modeling approach

AbstractThis work proposes an efficient cohesive finite element modeling approach based on a diffuse interelement interface strategy to reproduce the fracture behavior of quasi‐brittle materials under general loading conditions. The proposed model involves zero‐thickness interface elements, whose strength and toughness properties are spatially randomized, thus avoiding the well‐known nonuniqueness issues that can affect the stability of the associated numerical computations, which potentially lead to physically meaningless predictions of the fracture behavior. The reliability of the proposed refined fracture approach is assessed by performing several numerical simulations of the direct tensile test on various quasi‐brittle specimens. Results show that a proper calibration of the cohesive properties of the diffuse embedded interfaces is fundamental to ensure the desired numerical accuracy and stability properties. Besides, comparisons with experimental and numerical data found in the literature are used to fully validate the proposed approach.

Fracture behaviour of human skin in deep needle insertion can be captured using validated cohesive zone finite-element method

Medical needles have shown an appreciable contribution to the development of novel medical devices and surgical technologies. A better understanding of needle-skin interactions can advance the design of medical needles, modern surgical robots, and haptic devices. This study employed finite element (FE) modelling to explore the effect of different mechanical and geometrical parameters on the needle's force-displacement relationship, the required force for the skin puncture, and generated mechanical stress around the cutting zone. To this end, we established a cohesive FE model, and identified its parameters by a three-stage parameter identification algorithm to closely replicate the experimental data of needle insertion into the human skin available in the literature. We showed that a bilinear cohesive model with initial stiffness of 5000 MPa/mm, failure traction of 2 MPa, and separation length of 1.6 mm can lead to a model that can closely replicate experimental results. The FE results indicated that while the coefficient of friction between the needle and skin substantially changes the needle reaction force, the insertion velocity does not have a noticeable effect on the reaction force. Regarding the geometrical parameters, needle cutting angle is the prominent factor in terms of stress fields generated in the skin tissue. However, the needle diameter is more influential on the needle reaction force. We also presented an energy study on the frictional dissipation, damage dissipation, and strain energy throughout the insertion process.

Structural role of osteocyte lacunae on mechanical properties of bone matrix: A cohesive finite element study

Despite the extensive studies on biological function of osteocytes, there are limited studies that evaluated the structural role of osteocyte lacunae on local mechanical properties of the bone matrix. As a result, the goal of this study was to elucidate the independent contribution of osteocyte lacunae structure on mechanical properties and fracture behavior of the bone matrix uncoupled from its biological effects and bone tissue composition variation. This study combined cohesive finite element modeling with experimental data from a lactation rat model to evaluate the influence of osteocyte lacunar area porosity, density, size, axis ratio, and orientation on the elastic modulus, ultimate strength, and ultimate strain of the bone matrix as well as on local crack formation and propagation. It also performed a parametric study to isolate the influence of a single osteocyte lacunae structural property on the mechanical properties of the bone matrix. The experimental measurements demonstrated statistically significant differences in lacunar size between ovariectomized rats with lactation history and virgin groups (both ovariectomized and intact) and in axis ratio between rats with lactation history and virgins. There were no differences in mechanical properties between virgin and lactation groups as determined by the finite element simulations. However, there were statistically significant linear relationships between the physiological range of osteocyte lacunar area porosity, density, size, and orientation and the elastic modulus and ultimate strength of the bone matrix in virgin and lactation rats. The parametric study also revealed similar but stronger relationships between elastic modulus and ultimate strength and lacunar density, size, and orientation. The simulations also demonstrated that the osteocyte lacunae guided the crack propagation through local stress concentrations. In summary, this study enhanced the limited knowledge on the structural role of osteocyte lacunae on local mechanical properties of the bone matrix. These data are important in gaining a better understanding of the mechanical implications of the local modifications due to osteocytes in the bone matrix.

A cohesive XFEM model for simulating fatigue crack growth under various load conditions

This study presents calibration and validation of a cohesive extended finite element model for fatigue crack propagation in ductile materials. The approach relies on a separation between plasticity around the crack tip and fatigue crack growth at the crack tip such that the influence of plasticity on fatigue driving forces is predicted. This implies that characterization of crack growth requires effective Paris parameters. It is shown that the calibrated model can capture fatigue crack growth behaviour in ductile materials for in-phase and out-of-phase biaxial fatigue loading as well as in-phase biaxial loading with an overload.

A cohesive FE model for simulating the cracking/debonding pattern of composite NSC-HPFRC/UHPFRC members

The aim of this work is to propose to practitioners a simple cohesive Finite-Element (FE) model able to simulate the cracking/debonding pattern of retrofitted concrete elements, in particular Normal-Strength-Concrete members (slabs, bridge decks, pavements) rehabilitated by applying a layer of High-Performance or Ultra-High-Performance Fiber-Reinforced-Concrete as overlay. The interface was modeled with a proper nonlinear cohesive law which couples mode I (tension-crack) with mode II (shear-slip) behaviors. The input parameters of the FE simulation were provided by a new bond test which reproduces a realistic condition of cracking/debonding pattern. The FE simulations were accomplished by varying the overlay materials and the moisture levels of the substrate surface prior to overlay, since findings about their influence on the bond performances are still controversial. The proposed FE model proved to effectively predict the bond failure of composite NSC-HPFRC/UHPFRC members.

Mechanical damage behavior of metal matrix composites with the arbitrary morphology of particles

Metal matrix composites have significant applications in the engineering field. During service, the fracture is one of the most typical failure modes. In this study, the digital image-based technique (DIT) combined with a micro-scale damage cohesive finite element model (CFEM) was employed to reconstruct the microstructures of metal matrix composites with the arbitrary morphology of particles. The cohesive finite element in this model can predict the process of crack initiation and propagation spontaneously, and the effectiveness of the model was verified by the in-situ tensile tests of the compacted graphite iron (CGI) sample. We found that the morphology and distribution of the graphite particles play important roles in crack initiation and propagation under tensile and compressive loadings. The relationship between the graphite particle size and yield strength was established, and an optimal graphite particle size was found for the maximum yield strength, which is different from the previous results. The relationship between microstructures and tensile properties of CGI could contribute to the design and development of metal matrix composites with optimal mechanical properties.

Improve durability of plasma-splayed thermal barrier coatings by decreasing sintering-induced stiffening in ceramic coatings

In this study, a newly-tailored plasma-sprayed (PS) yttria-stabilized zirconia (YSZ) ceramic coating towards enhanced strain tolerance and sintering resistance was developed to improve the durability of TBCs. The thermal shock life was found to be markedly prolonged by more than four times. Failure mechanisms and sintering behavior of the newly-structured and conventional TBCs were systematically investigated through microstructural and mechanical analyses. Conventional TBCs suffered a premature spallation due to rapid sintering-induced stiffening of the ceramic top coat. In contrast, the new coating exhibits an enhanced sintering resistance whereby preserving a good strain tolerance over time. Specifically, its elastic modulus after thermal exposure remains comparable to the as-sprayed states. The effect of ceramic top coat stiffness on cracking behavior of TBCs was clarified by a corresponding cohesive zone finite element modeling. This study provides a new option for improving TBCs durability and the results could benefit the increased integrity of TBCs.

CHARACTERIZATIONS ON FRACTURE PROCESS ZONE OF PLAIN CONCRETE

The fracture property of concrete is essential for the safety and durability analysis of concrete structures. Investigating the characteristics of the fracture process zone (FPZ) is of great significance to clarify the nonlinear fracture behaviour of concrete. Experimental and numerical investigations on the FPZ of plain concrete in pre-notched beams subjected to three-point bending were carried out. Electronic speckle pattern interferometry (ESPI) technique was used to observe crack evolution and measure the full-field deformation of the beams. The development of the FPZ were evaluated qualitatively and quantitatively based on the in-plane strain contours and displacement field measured by ESPI, respectively. By integrating the cohesive crack model and finite element (FE) model, various tension softening curves (TSCs) were employed to simulate the fracture response of concrete beams. By comparing the deformation obtained by FE simulation and experiments, the TSCs of plain concrete were evaluated and most suitable TSCs of concrete were recommended.

Computational investigation of the effect of water on the nanomechanical behavior of bone

Previous experimental and computational studies have indicated that removing bound water in bone matrix makes bone stiffer, stronger, but more brittle at different length scales. However, a clear mechanistic explanation of the underlying mechanisms is lacking. Assuming that bound water mainly alters the mechanical behavior of collagen phase and the interfaces among bone constituents, this study investigated the effects of bound water on the mechanical properties of bone using a 2D cohesive finite element (FE) model representing the sub-lamellar hierarchy of the tissue. The model contained sufficient ultrastructural details of mineralized collagen fibrils (MCF), extrafibrillar matrix (EFM), and the interfaces among bone constituents. The mechanical behavior of the interfaces, and mineral/collagen phases, in the hydrated and dehydrated conditions was carefully selected based on the information available in the literature. The FE simulations indicated that hydration status induced changes at the interfaces played a key role in determining the mechanical behavior of bone. In tension, hydrated interfaces (weak but tough) in bone appeared to encourage multiple nanocrack formation, debonding between the MCF and EFM subunits, and crack bridging by MCFs. On the other hand, dehydrated (strong but brittle) interfaces made the tissue stiffer and stronger, but compromised the above energy dissipation mechanisms, thus leading to a brittle failure. In compression, hydrated interfaces resulted in sliding between the mineral crystals in EFM, debonding between EFM and MCF, and buckling of MCF, whereas dehydrated interfaces appeared to make the tissue stiffer and stronger and the energy dissipation mechanisms diminished. The outcome of this study provides new insights into the mechanisms underlying the effect of bound water on bone fragility at ultrastructural levels.

Computational modelling of multi-stage hydraulic fractures under stress shadowing and intersecting with pre-existing natural fractures

The key objective of this work is to establish a fully coupled pore pressure and stress model in order not only to investigate multi-stage hydraulic fractures (HFs) according to several completion designs, but also to study the complex problem of intersection of an HF and a pre-existing natural fracture (NF). First, this work concentrates on a computational finite element model based on the cohesive phantom node method (CPNM) to simulate initiation and propagation of multiple curving fractures. The primary contribution of this part is to shed light on the stress shadowing effect on conventional completion designs, i.e. simultaneous HF (Sim-HF) and sequential HF (Seq-HF), and in particular newly introduce the Texas two-step method (TTSM). Furthermore, the rock medium in the entire simulation domain is considered using the elasto-plastic constitutive equations of the Mohr–Coulomb and Drucker–Prager models. The impact of formation plasticity on the fracturing process is investigated, and the results obtained are compared with those based on the poro-elastic model. Second, in order to simulate the intersection of an HF with an NF, a cohesive crack-based finite element model (CCFEM) is developed along with a novel technique for the HF/NF intersection. Implementation of this technique at the intersection of HF and NF is considerably more straightforward in comparison with those in the available literature. In addition, this part aims at highlighting the crucial role of horizontal stress contrast in determining the type of HF/NF intersection scheme.

Computational investigation of ultrastructural behavior of bone using a cohesive finite element approach.

Bone ultrastructure at sub-lamellar length scale is a key structural unit in bone that bridges nano- and microscale hierarchies of the tissue. Despite its influence on bulk response of bone, the mechanical behavior of bone at ultrastructural level remains poorly understood. To fill this gap, in this study, a two-dimensional cohesive finite element model of bone at sub-lamellar level was proposed and analyzed under tensile and compressive loading conditions. In the model, ultrastructural bone was considered as a composite of mineralized collagen fibrils (MCFs) embedded in an extrafibrillar matrix (EFM) that is comprised of hydroxyapatite (HA) polycrystals bounded via thin organic interfaces of non-collagenous proteins (NCPs). The simulation results indicated that in compression, EFM dictated the pre-yield deformation of the model, then damage was initiated via relative sliding of HA polycrystals along the organic interfaces, and finally shear bands were formed followed by delamination between MCF and EFM and local buckling of MCF. In tension, EFM carried the most of load in pre-yield deformation, and then an array of opening-mode nano-cracks began to form within EFM after yielding, thus gradually transferring the load to MCF until failure, which acted as crack bridging filament. The failure modes, stress-strain curves, and in situ mineral strain of ultrastructural bone predicted by the model were in good agreement with the experimental observations reported in the literature, thus suggesting that this model can provide new insights into sub-microscale mechanical behavior of bone.

Axial-torsional high-cycle fatigue of both coarse-grained and nanostructured metals: A 3D cohesive finite element model with uncertainty characteristics

In this study the combined axial–torsional fatigue life and damage evolution of both coarse-grained (CG) and nanostructured metals are modeled by a 3D cohesive finite element method with uncertainty characteristics. To account for the random nature of metal fatigue, we combine the Monte Carlo simulation with the three-parameter Weibull statistical distribution function. For both CG and nanostructured metals, we find that the axial load levels have greater effects than random fields on the amplitude of specimen rotation. Compared with the CG metals, the nanostructured metals are found to exhibit an improved fatigue resistance, for the reason that their damage process initiates from the subsurface beneath the nanograined layer and then extends to the exterior surface. Good agreements between the numerical results and experimental data are also observed. It shows the applicability of the 3D cohesive finite element method for the analysis of damage evolution and prediction of fatigue life in these two classes of metals.

Experimental and numerical investigation on the bond strength of self-sensing composite joints

Laboratory experiments demonstrate that a novel carbon nanotube (CNT)-based sensing layer embedded in the bondline of an adhesively bonded structural joint can detect and monitor deformation and damage progression of the adhesive layer. In this study, experimental and numerical investigations were performed to identify any effect of an embedded CNT-based sensing layer on the bond strength of that joint. To evaluate the mechanical behavior of such a bondline configuration, two sets of single-lap specimens, with and without sensing layer, were prepared and tested to determine the bond strengths of the respective types. Two-dimensional digital image correlation (2D DIC) was utilized to estimate the load-displacement response of the test specimens. Three-dimensional cohesive surface finite element models of the test specimens, with and without the sensing layer, were created and validated using the experimental measurements. It is shown that the embedded CNT-based sensing layer does not influence the bond strength of the single-lap joint.