Finite element analysis testing

Strain gages may be applied to the test unit at all points where high stresses are anticipated, provided that the configuration of the units permits such techniques. The use of finite element analysis, models, brittle lacquer, etc., is recommended to confirm the proper location of strain gages. Three-element strain gages are recommended in critical areas to permit determination of the shear stresses and to eliminate the need for exact orientation of the gages. 

There are of course products whose shapes do not approximate a simple standard form or where more detailed analysis is required, such as a hole, boss, or attachment point in a section of a product. With such shapes the component s geometry complicates the design analysis for plastics, glass, metal, or other material and may make it necessary to carry out a direct analysis, possibly using finite element analysis (FEA) followed with prototype testing. Examples of design concepts are presented. 

In particular, the techniques based on the termination of certain plies within the laminate has also shown promise. Static tensile tests of [30°/-30°/30°/90°]s carbon-epoxy laminates containing terminals of [90°] layers at the mid-plane show that premature delamination is completely suppressed with a remarkable 20% improvement in tensile strength, compared to those without a ply terminal. Cyclic fatigue on the same laminates confirms similar results in that the laminate without a ply terminal has delamination equivalent to about 40% of the laminate width after 2x10 cycles, whereas the laminates with a ply terminal exhibit no evidence of delamination even after 9x10 cycles. All these observations are in agreement with the substantially lower interlaminar normal and shear stresses for the latter laminates, as calculated from finite element analysis. A combination of the adhesive interleaf and the tapered layer end has also been explored by Llanos and Vizzini, (1992). 

PP bead foams were subjected to oblique impacts, in which the material was compressed and sheared. This strain combination could occur when a cycle helmet hit a road surface. The results were compared with simple shear tests at low strain rates and to uniaxial compressive tests at impact strain rates. The observed shear hardening was greatest when there was no imposed density increase and practically zero when the angle of impact was less than 15 degrees. The shear hardening appeared to be a unique function of the main tensile extension ratio and was a polymer contribution, whereas the volumetric hardening was due to the isothermal compression of the cell gas. Foam material models for finite element analysis needed to be reformulated to consider the physics of the hardening mechanisms, so their predictions were reliable for foam impacts in which shear occurred. 16 refs. 

Tack is, of course, of great importance for adhesives and many methods have been used. A summary of work on testing and finite element analysis of adhesive tack has been given136 and it has been questioned whether the methods used for pressure sensitive adhesives really work137. 

The main interest in finite element analysis from a testing point of view is that it requires the input of test data. The rise in the use of finite element techniques in recent years is the reason for the greatly increased demand for stress strain data presented in terms of relationships such as the Mooney-Rivlin equation given in Section 1 above. 

There is a British standard19 giving guidance on the application of rubber testing to finite element analysis. Several of the models for stress strain behaviour are appraised and advice given on selection. The point is made that the models considered treat the rubber as a perfectly elastic material,... 

Whilst it is generally held that an extensometer is necessary, it would be rather less expensive if elongation of dumbbells could be obtained from crosshead movement. Tay and Teoh76 devised a numerical scheme whereby the stress strain characteristics could be derived from measured load versus total elongation data from a finite element analysis of the dumb-bell shape. Their method was shown to work to within 10% of values measured with an infra red extensometer for two fairly soft plastics and a silicone rubber. To be effective, the tensile test must be carried out with grips which essentially prevent any slippage and it is, of course, necessary to have the computing facility set up to carry out the analysis. 

If compression stress strain is used to obtain input data for finite element analysis, the tests would be made with lubricated platens. ISO 7743 does not mention that if the lubrication really is near perfect the test piece can have the unfortunate habit of slipping out of the platens. To prevent this, a small pin should project from the centre of one platen. 

Stress/strain relationships for other torsional configurations can be found in Engineering Design with Rubber119 and Yeoh120 examined the torsion of cylindrical test pieces by finite element analysis. 

Tearing energy can be computed by finite element analysis and Yeoh150 has applied this to some classical test piece shapes to address some unanswered questions. 

BS 903-5, 2004. Guide to the application of rubber testing to finite element analysis. 

In the present work, a novel experimental method was proposed to evaluate the modes I-fll fracture toughness of the adhesive interface between concrete and carbon fiber sheets. The validity of the evaluation formula was studied on the basis of the results of finite element analysis. The mixed mode fracture toughness and fracture criterion of the adhesive interface were also studied on the basis of the results of fracture toughness test using the proposed method. 

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