Abstract

Although laminated materials have been used for decades, their employment has increased nowadays in the last years as a result of the gained confidence of the industry on these materials. This has provided the scientific community many reasons to dedicate considerable amount of time and efforts to address a better understanding of their mechanical behavior. With this objective both, experimental and numerical simulation have been working together to give response to a variety of problems related with these materials.

Regarding numerical simulation, a correct modeling of the kinematics of laminated materials is essential to capture the real behavior of the structure. Moreover, once the kinematics of the structure has been accurately predicted other non-linear phenomena such as damage and/or plasticity process could be also studied.

In consequence, in order to contribute to the constant development of simpler and more efficient numerical tools to model laminated materials, a numerical method for modeling mode II/III delamination in advanced composite materials using one-and two-dimensional finite elements is proposed inthis work. In addition, two finite elements base on a zigzag theory for simulating higly heterogeneous multilayered beams and plates structures are developed here.

The document is written based on results of four papers published in indexed journals. Copies of all these papers are included in Appendix. The main body of this thesis is constituted by Chapters 2 to 4. Chapter 2 deals with the numerical treatment of laminated beams and plates. Chapter 3 presents the formulation of the LRZ beam and the QLRZ plate finite elements based on the Refined Zigzag theory. Finally, the main contribution of this thesis, the LRZ/QLRZ delamination model, is developed in Chaptert 4.

Abstract

Predicting the bearing capacity of resistance spot welds (RSW) during vehicle crash tests has become a crucial task for the automotive industry, since the recent introduction of advanced high strength steels (AHSS) such as martensitic boron steels (e.g. 22MnB5). The spot weld joints of these steels exhibit relatively low bearing strengths, compared to those of more ductile high strength steels. Currently, the bearing capacity of spot weld joints is characterized through extensive experimental campaigns. In this article, a model for quantification of the bearing capacity of RSW using a finite-element J-integral fracture criterion is presented. The model takes into account geometric and mechanical features of the spot weld, namely the weld diameter and the mechanical properties distribution resulting from the welding process. An experimental loading test campaign is carried out for calibration and validation purposes, considering multiple sheet thickness combinations, loading angles and weld sizes. Experimental observations of the failed spot welds and preliminary simulations show that failure is caused mostly by stress concentration around the sharp weld notch. Consequently, the J-integral obtained from detailed finite element simulations is used to asses the stress/strain concentration along the first crack advance direction predicted by the acoustic tensor. The computed J-integral values are compared to the material toughness to obtain the joint’s maximum force. The resulting simulated and experimental bearing capacities show a good agreement for all tested configurations.

Abstract

Fork’s related structural design and detail have a significant impact on the overall performance of a forklift. In this paper, the structural stress analysis and strength calculation of the fork were carried out firstly, and the rated load calculations considering dynamic and unbalanced conditions were performed. Also, the restraint conditions were analyzed. Then, a finite element model was established using ANSYS software. In particular, the fork’s structure was optimized by increasing the fillet radius of the fork root and the variation rules between the fillet radius and the maximum structural stress and minimum fatigue life were numerically studied, which was in accordance with the mathematical models of ExpAssoc and Logistic regression, and the corresponding fitting coefficients of R2 was respectively equal to 0.99 and 0.96. Overall, the stress concentration issue of the fork root was improved and the structural strength perquisite was satisfied when using a fillet radius of 75 mm. Both the numerical calculations and theorized mechanical analysis show consistency, where the stress concentration was observed in the fork root’s fillet area, testifying the accuracy of the established finite element model. The numerous methods employed in this work lay an important theoretical basis for the structural optimization of the target fork.

Abstract