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Honeycomb structures made of carbon-fiber-reinforced plastic (CFRP) are increasingly used in the aerospace field due to their excellent energy absorption capability. Attention has been paid to CFRP structures in order to accurately simulate their progressive failure behavior and discuss their ply designability. In this study, the preparation process of a CFRP corrugated sheet (half of the honeycomb structure) and a CFRP honeycomb structure was illustrated. The developed finite element method was verified by a quasi-static test, which was then used to predict the low-velocity impact (LVI) behavior of the CFRP honeycomb, and ultimately, the influence of the ply angle and number on energy absorption was discussed. The results show that the developed finite element method (including the user-defined material subroutine VUMAT) can reproduce the progressive failure behavior of the CFRP corrugated sheet under quasi-static compression and also estimate the LVI behavior. The angle and number of plies of the honeycomb structure have an obvious influence on their energy absorption under LVI. Among them, energy absorption increases with the ply number, but the specific energy absorption is basically constant. The velocity drop ratios for the five different ply angles are 79.12%, 68.49%, 66.88%, 66.86%, and 60.02%, respectively. Therefore, the honeycomb structure with [0/90]s ply angle had the best energy absorption effect. The model proposed in this paper has the potential to significantly reduce experimental expenses, while the research findings can provide valuable technical support for design optimization in aerospace vehicle structures.

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This study aims to critically assess different micromechanical analysis models applied to carbon-fiber-reinforced plastic (CFRP) composites, employing micromechanics-based homogenization to accurately predict their effective properties. The paper begins with the simplest Voigt and Reuss models and progresses to more sophisticated micromechanics-based models, including the Mori-Tanaka and Method of Cells (MOC) models. It provides a critical review of the areas in which these micromechanics-based models are effective and analyses of their limitations. The numerical analysis results were confirmed through finite element simulations of the periodic representative volume element (RVE). Furthermore, the effective properties predicted by these micromechanics-based models were validated via experiments conducted on IM7/5320-1 composite material with a fiber volume fraction of 0.62.

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The spring-in phenomenon of the composite parts can affect the assembly process. This study aims to predict the spring-in phenomenon of a carbon fiber reinforced plastic (CFRP) part. Here, we predict the spring-in of the CFRP part using a coupled analysis of the forming and cooling processes during the stamping process. First, a simulation of the entire forming process, such as the transfer of the composite laminate, gravity analysis, and forming was performed to obtain the temperature distribution of the CFRP part. Subsequently, a finite-element (FE) simulation of the cooling process was conducted to predict the spring-in phenomenon of the shaped CFRP part using the temperature data obtained in the forming simulation. Finally, a CFRP part was manufactured and compared with the results of the FE simulation.

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Laminated plates are often modeled with infinite dimensions in terms of the so-called Whitney-Nuismer (WN) stress criteria, which form a theoretical basis for predicting the residual properties of open-hole structures. Based upon the WN stress criteria, this study derived a new formulation involving finite width; the effects of notch shape and size on the applicability of new formulae and the tensile properties of carbon-fiber-reinforced plastic (CFRP) laminates were investigated via experimental and theoretical analyses. The specimens were prepared by using laminates reinforced by plain woven carbon fiber fabrics and machined with or without an open circular hole or a straight notch. Standard tensile tests were performed and measured using the digital image correlation (DIC) technique, aiming to characterize the full-field surface strain. Continuum damage mechanics (CDMs)-based finite element models were developed to predict the stress concentration factors and failure processes of notched specimens. The characteristic distances in the stress criterion models were calibrated using the experimental results of un-notched and notched specimens, such that the failure of carbon fiber laminates with or without straight notches could be analytically predicted. The experimental results demonstrated well the effectiveness of the present formulations. The new formula provides an effective approach to implementing a finite-width stress criterion for evaluating the tensile properties of notched fiber-reinforced laminates. In addition, the notch size has a great effect on strength prediction while the fiber direction has a great influence on the fracture mode.

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Globally, the demand for carbon fiber-reinforced thermosetting plastics for various applications is increasing. As a result, the amount of waste from CFRPs is increasing every year, and the EU Council recommends recycling and reuse of CFRPs. Epoxy resin (EP) is used as a matrix for CFRPs, and amine hardeners are mainly used. However, no research has been conducted on recycling EP/4,4'-diaminodiphenyl sulfone (DDS)-based CFRP. In this study, the effect of steam and air pyrolysis conditions on the mechanical properties of re-cycled carbon fiber (r-CF) recovered from carbon fiber-reinforced thermosetting (epoxy/4,4'-diaminodiphenyl sulfone) plastics (CFRPs) was investigated. Steam pyrolysis enhanced resin degradation relative to N2. The tensile strength of the recovered r-CF was reduced by up to 35.12% due to oxidation by steam or air. However, the interfacial shear strength (IFSS) tended to increase by 9.18%, which is considered to be due to the increase in functional groups containing oxygen atoms and the roughness of the surface due to oxidation. The recycling of CFRP in both a steam and an air atmosphere caused a decrease in the tensile strength of r-CF. However, they were effective methods to recover r-CF that had a clean surface and increased IFSS.

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When impact damage occurs in carbon fiber-reinforced plastic (CFRP) structures, it is barely visible but may cause significant degradation in the mechanical properties of the structure. Hence, a structural health monitoring (SHM) system that can be installed in CFRP mobility structures and is sensitive to impact damage is needed. In this study, we attempted to establish an SHM system based on ultrasonic guided waves, which are generated by inputting a broadband chirp signal into a film-like piezoelectric actuator. The relationship between impact damage size and maximum time-of-flight (ToF) delay was investigated for three types of CFRP plates: woven, non-woven, and hybrid laminates. As a result, it was found that the maximum ToF delay increased linearly with an increase in the damage size for all CFRP laminates. Moreover, the amplitude of the A0 mode was found to be significantly affected by the damage length in the wave propagation direction. Thus, this SHM method using chirp ultrasonic waves can quantitatively evaluate the size and extent of the impact damage in CFRP laminates.

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OBJECTIVES: Carbon fibers are used in a variety of industrial applications, based on their lightweight and high stiffness properties. There is little information on the characteristics and exposure levels of debris generated during the factory processing of carbon fibers or their composites. This study revisits the general assumption that carbon fibers or their debris released during composite processing are considered safe for human health. METHODS: The present interventional study was conducted at a factory located in Japan, and involved on-site collection of debris generated during the industrial processing of polyacrylonitrile (PAN)-based carbon-fiber-reinforced plastic (CFRP). The debris were collected before being exhausted locally from around different factory machines and examined morphologically and quantitatively by scanning electron microscopy. The levels of exposure to respirable carbon fibers at different areas of the factory were also quantified. RESULTS: The collected debris mainly contained the original carbon fibers broken transversely at the fiber's major axis. However, carbon fiber fragments morphologically compatible with the WHO definition of respirable fibers (length: > 5 µm, width: < 3 µm, length/width ratio: > 3:1) were also found. The concentrations of respirable fibers at the six examined factory areas under standard working conditions in the same factory were below the standard limit of 10 fibers/L, specified for asbestos dust-generating facilities under the Air Pollution Control Law in Japan. CONCLUSIONS: Our study identified potentially dangerous respirable fibers with high aspect ratio, which was generated during the processing of PAN-based CFRP. Regular risk assessment of carbon fiber debris is necessary to ensure work environment safety.

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The purpose of this study was to predict the adhesive behavior of steel and carbon-fiber-reinforced plastic (CFRP) hybrid parts based on the cohesive zone model (CZM). In this study, the steel sheet and CFRP were joined by epoxy resin in the CFRP prepreg during the curing process, which could generate delamination at their interface because of the springback of steel or the thermal contraction of the CFRP. First, double cantilever beam (DCB) and end-notched flexure (ENF) tests were performed to obtain various adhesion properties such as the critical energy release rate of mode I, mode II (GI, GII), and critical stress (σmax). A finite element (FE) simulation was performed to predict delamination using CZM, which was also used to describe the interfacial behavior between the steel sheet and the CFRP. Finally, a U-shape drawing test was performed for the steel/CFRP hybrid parts, and these results were compared with analytical results.

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This study describes the numerical simulation results of aluminum/carbon-fiber-reinforced plastic (CFRP) hybrid joint parts using the explicit finite-element solver LS-DYNA, with a focus on capturing the failure behavior of composite laminates as well as the adhesive capacity of the aluminum-composite interface. In this study, two types of adhesive modeling techniques were investigated: a tiebreak contact condition and a cohesive zone model. Adhesive modeling techniques have been adopted as a widely commercialized model of structural adhesives to simulate adhesive failure based on fracture mechanics. CFRP was studied with numerical simulations utilizing LS-DYNA MAT54 to analyze the crash capability of aluminum/CFRP. To evaluate the simulation model, the results were compared with the force-displacement curve from numerical analysis and experimental results. A parametric study was conducted to evaluate the effect of different fracture toughness values used by designers to predict crash capability and adhesive failure of aluminum/CFRP parts.

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This study addressed the topology optimization of a carbon fiber reinforced plastic (CFRP) laminated battery-hanging structure of an electric vehicle. To accommodate parameterization for thickness and orientation of CFRP materials, the discrete material and thickness optimization (DMTO) technique was adopted. To include metal material as a reinforcement structure into the optimization simultaneously, the DMTO technique was extended here to achieve concurrent optimization of CFRP thickness topology, CFRP orientation selection and the topology of the metal reinforcement plate. Manufacturing constraints were applied, including suppressing intermediate void across the thickness direction of the laminate, contiguity constraint and the symmetrical layers. Sensitivities of the objective function were derived with respect to design variables. To calculate analytical sensitivities, finite element analysis was conducted and strain vectors were exported from a commercial software (ABAQUS) into a mathematical analysis tool (MATLAB). The design objective was to minimize the local displacement subject to the constraints of manufacturing and mass fraction. The mechanical performance of the optimized CFRP structure was compared with the original steel structure. To validate the optimization results, a prototype of the CFRP battery-hanging structure was fabricated and experimental testing was conducted. The results show that the total mass of the CFRP battery-hanging structure was reduced by 34.3% when compared with the steel one, while the mechanical property was improved by 25.3%.

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The increasing utilization of carbon fiber reinforced plastic (CFRP) in the aeronautical industry calls for a structural health monitoring (SHM) system for adhesively bonded CFRP joints. Optical glass fiber with inscribed fiber Bragg gratings (FBGs) is a promising technology for a SHM system. This paper investigates the intrusive effect of embedding optical glass fibers carrying FBGs on adhesive bond strength and adhesive layer thickness and quality. Embedding the optical glass fibers directly in the adhesive bond has the advantage of directly monitoring the targeted structure but poses the risk of significantly reducing the bond strength. Optical glass fibers with different cladding diameters (50, 80, 125 µm) and coating types (polyimide, with a thickness of 3-8 µm, and acrylate, with a thickness of ~35 µm) are embedded in structural and repair film adhesives here. Without embedded optical glass fibers, the film adhesives have an adhesive layer thickness of ~90 µm (structural) and ~100 µm (repair) after curing. The intrusive effect of the fiber embedding on the adhesive bond strength is investigated here with quasi static and fatigue single lap joint (SLJ) tensile shear tests. Also, the influence of hydrothermal aging procedures on the quasi static tensile shear strength is investigated. It is found that optical glass fibers with a total diameter (glass fiber cladding + coating) of ~145 µm significantly reduce the quasi static tensile shear strength and increase the adhesive layer thickness and number of air inclusions (or pores) in the structural film adhesive joints. In the repair adhesive joints, no significant reduction of quasi static tensile shear strength is caused by the embedding of any of the tested fiber types and diameters. However, an increase in the adhesive layer thickness is detected. In both adhesive films, no effect on the quasi-static tensile shear strength is detected when embedding optical glass fibers with total diameters <100 µm. The applied aging regime only affects the repair film adhesive joints, and the structural film adhesive joints show no significant reduction. A polyimide-coated 80 µm optical glass fiber is selected for fatigue SLJ tensile shear tests in combination with the more sensitive structural film adhesive. No significant differences between the S-N curves and tensile shear fatigue strength of the reference samples without embedded optical fibers and the samples carrying the polyimide-coated 80 µm optical glass fibers are detected. Thus, it is concluded that the influences of embedding optical glass fibers with total diameters <100 µm on the fatigue limit of the tested film adhesive joints is negligible.

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Mechanical properties, such as strength and stiffness, of laminated carbon fiber reinforced plastic (CFRP) are generally affected by the lay-up method. However, no precise design rules to replace steel products with CFRP have been established that satisfy these properties. Therefore, this study proposes a set of rules to design automotive parts with equivalent bending stiffness through structural analysis and genetic algorithms (GAs). First, the thickness of the CFRP product was determined by comparing the bending deformation of steel products by structural analysis. To minimize the orthotropic characteristics of CFRP, the quasi-isotropic lay-up method was implemented to determine the thickness. Next, the lay-up angle was determined using GAs. The optimized lay-up angle of the CFRP product with minimum bending deformation was determined by population generation, cross-over, mutation, and fitness evaluation. CFRP B-pillar reinforcement was fabricated using the determined conditions and the bending deformation of the single component was evaluated. Finally, the B-pillar assembled with CFRP reinforcement was investigated by the drop tower test.

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A pulsed laser illuminates a target zone that causes rapid thermoelastic expansion, generating broadband high-frequency ultrasonic wave (photoacoustic wave, PA wave). We developed a PA microscopy (PAM) with a confocal area of laser and ultrasonic wave for applications in nondestructive testing (NDT). The synthetic aperture focusing technique (SAFT) is applied in the PAM for the three-dimensional (3D) imaging of interior flaws. Here, we report proof-of-concept experiments for the NDT of a subsurface flaw in a thin laminar material. Graphical abstract (a) shows a specimen of carbon-fiber-reinforced plastic (CFRP) with an artificial delamination. Here, it should be noted that the group velocity varies directionally due to the strong anisotropy of the CFRP specimen (see Graphical abstract (b)). By considering the group velocity distribution in the SAFT, the shape and location of the subsurface delamination were accurately estimated as shown in Graphical abstract (c). Coating the surface of the CFRP specimen with a light-absorbent material improved the amplitude of the PA wave. This finding showed that the signal-to-noise ratio of the waves scattered from the flaws can be improved.

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A multiscale analysis strategy with physical modified-micromechanics of failure (MMF3) criterion was proposed to analyze the failure behaviors of carbon fiber reinforced plastic (CFRP) laminates. The quantitative relationship between the macro- and micro- stresses was determined considering two typical fiber distributions. Thermal residual stress was taken into account in the stress transformation. The failures were defined and the properties of damaged elements were degraded at the constituent level. The back-calculation method based on the iteration algorithm was proposed to determine the micro strength with macro mechanical tests. A series of off-axis loading tests were conducted to verify the established multiscale models. The predicted strength was also compared with the results using micromechanics of failure (MMF) criterion to present accuracy improvements. Thermal residual stress was found to affect the strength by contributing to the matrix damage status. Meanwhile, sensitivity analysis was provided for the matrix-dominant micro strength to investigate its physical meaning. Results suggest that the micro tensile and compressive strength of the matrix influenced the off-axis tensile and compressive strengths respectively, with relative large off-axis angles, while the micro shear strength of the matrix dominated when the off-axis angles were relative small.

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Hole quality plays a crucial role in the production of close-tolerance holes utilized in aircraft assembly. Through drilling experiments of carbon fiber-reinforced plastic composites (CFRP), this study investigates the impact of varying drilling feed and speed conditions on fiber pull-out geometries and resulting hole quality parameters. For this study, hole quality parameters include hole size variance, hole roundness, and surface roughness. Fiber pull-out geometries are quantified by using scanning electron microscope (SEM) images of the mechanically-sectioned CFRP-machined holes, to measure pull-out length and depth. Fiber pull-out geometries and the hole quality parameter results are dependent on the drilling feed and spindle speed condition, which determines the forces and undeformed chip thickness during the process. Fiber pull-out geometries influence surface roughness parameters from a surface profilometer, while their effect on other hole quality parameters obtained from a coordinate measuring machine is minimal.

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Carbon fiber reinforced plastic (CFRP) composites have been intensively used in various industries due to their superior properties. In aircraft and aerospace industry, a large number of holes are required to be drilled into CFRP components at final stage for aircraft assembling. There are two major types of methods for hole making of CFRP composites in industry, twist drilling and its derived multi-points machining methods, and grinding and its related methods. The first type of methods are commonly used in hole making of CFRP composites. However, in recent years, rotary ultrasonic machining (RUM), a hybrid machining process combining ultrasonic machining and grinding, has also been successfully used in drilling of CFRP composites. It has been shown that RUM is superior to twist drilling in many aspects. However, there are no reported investigations on comparisons between RUM and grinding in drilling of CFRP. In this paper, these two drilling methods are compared in five aspects, including cutting force, torque, surface roughness, hole diameter, and material removal rate.