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Abstract: This paper investigates the local buckling of slit tape in the Automated Fibre Placement process for a circular fibre path using an analytical approach that accounts for prepreg tack and stress distribution. Curing effects are not considered in this study. The main objective is to define the critical buckling load and therefore the minimal steering radius for which no tow wrinkling occurs. Simulations are performed for the buckling of the first ply, using a tack parameter governing the interaction between tool and material. A sensitivity analysis of the most relevant parameters of the model is performed. Numerical results show that lower values of the steering radius are obtained for lower tow width values and higher prepreg tack values. Experimental investigations show that the estimation of wrinkling occurrence in steered fibres could be improved by taking into account certain additional parameters, such as lay-down rate, temperature and the dynamic behaviour of the resin. [Copyright &y& Elsevier]

Abstract: Two-dimensional (2D) hierarchical cellular materials made up of sandwich walls are predicted to have superior mechanical properties compared with solid-wall cellular materials. Equations of the stiffness, the buckling strength, the plastic collapse strength, the brittle failure strength and the fracture toughness were deduced. The enhancement of the mechanical properties of 2nd order hierarchical honeycombs is substantial (even an order of magnitude). The hierarchical honeycomb is much more damage tolerant and insensitive to wavy imperfections of the cell wall. Sandwich struts also enhance the buckling strength of the stretching-dominated 2nd order lattice grid material. Made up of sandwich struts, the hierarchical honeycomb has comparable mechanical properties with the stretching-dominated lattice grid material. [Copyright &y& Elsevier]

Abstract: A novel corrugated composite core, referred to as a hierarchical corrugation, has been developed and tested experimentally. Hierarchical corrugations exhibit a range of different failure modes depending on the geometrical properties and the material properties of the structures. In order to understand the different failure modes the analytical strength model, developed in part 1 of this paper, was used to make collapse mechanism maps for the different corrugation configurations. If designed correctly, the hierarchical structures can have more than 7 times higher weight specific strength compared to its monolithic counter part. The difference in strength arises mainly from the increase in buckling resistance of the sandwich core members compared to the monolithic version. The highest difference in strength is seen for core configurations with low overall density. As the density of the core increases, the monolithic core members get stockier and more resistant to buckling and thus the benefits of the hierarchical structure reduces. [Copyright &y& Elsevier]

Abstract: A fuselage representative carbon fibre-reinforced multi-stiffener panel is analysed under compressive loading. An intact and pre-damaged configuration is loaded into the postbuckling region and further on until collapse occurs. An analysis tool is applied that includes an approach for predicting interlaminar damage initiation and degradation models for capturing interlaminar damage growth as well as in-plane damage mechanisms. Analysis of the intact panel configuration predicts collapse due to fibre fracture in the stiffeners close to the panel clamps, which agrees well with the results from experimental testing. The pre-damaged configuration was proposed containing Teflon-coated layers to generate the initial debonds in the skin-stiffener interface. The outcome of the simulation of this configuration shows that crack growth is not predicted to occur, which agrees with the observations of the experiment. A parametric study is conducted to investigate the effect of the skin-stiffener debond parameters such as length, width and location on crack growth and the collapse behaviour of the panel. It is found that the sensitivity of the panel design to the damage parameters is highly dependent on the postbuckling mode shape or displacement pattern, and particularly the extent to which this influences the conditions at the crack front. More broadly, the analysis tool is shown to be capable of capturing the critical damage mechanisms leading to structural collapse of stiffened composite structures in the postbuckling region. [Copyright &y& Elsevier]

Abstract: Filament winding and twice co-curing processes were proposed to make a carbon fiber reinforced composite (CFRC) sandwich cylinder with Kagome cores. Axial compression was carried out to reveal the stiffness and load capacity of the fabricated sandwich cylinder. Compared with the stiffened cylinder with similar dimensions and mass, the sandwich cylinder is shown to be stiffer and stronger by several times. Restrained by the double skins, the buckling of lattice ribs is effectively suppressed, leading to the elimination of the dominant failure mode. Skin crippling and strength failure were observed in the testing to be the competing failure mechanisms of the lattice sandwich cylinder. The prediction based on the weakest link of these mechanisms only overestimates the testing load capacity by 30%. The novel sandwich structure shows the promise of lattice composites in upgrading the mechanical properties. [Copyright &y& Elsevier]

Abstract: A shear loaded, stringer reinforced composite panel is analyzed to evaluate the fidelity of computational fracture mechanics analyses of complex structures. Shear loading causes the panel to buckle. The resulting out-of-plane deformations initiate skin/stringer separation at the location of an embedded defect. The panel and surrounding load fixture were modeled with shell elements. A small section of the stringer foot, web and noodle as well as the panel skin near the delamination front were modeled with a local 3D solid model. Across the width of the stringer foot, the mixed-mode strain energy release rates were calculated using the virtual crack closure technique. A failure index was calculated by correlating the results with a mixed-mode failure criterion of the graphite/epoxy material. The objective was to study the effect of the fidelity of the local 3D finite element model on the computed mixed-mode strain energy release rates and the failure index. [Copyright &y& Elsevier]