The role of cork powder as a compatibilizing filler of synthetic materials used to putty shrinkage cracks of wood

Topology Optimization Design of Internal Reinforcements in a Sailing Dinghy

AbstractIn this paper, a novel approach has been followed based on FEM simulation and Topology Optimization tools to locate and model the reinforcements inside the hull of a sailing dinghy. This process assumes that the inner volume included between the hull and the deck is, at the beginning of the simulation, filled with material; then a portion of this inner volume is eroded until a final free form shape of the reinforcements is obtained. A key point of this procedure is the definition of the optimization constrains because the final shape of the reinforcements must fulfill several requirements such as weight, stiffness and stress. At the end of the optimization procedure, the final shape…

Simulation of fatigue delamination growth in composites with different mode mixities

STUDIO DI GIUNZIONI METALLO-COMPOSITO SOTTOPOSTE A CARICHI STATICI E DI FATICA

Obiettivo di questo studio è l’analisi delle giunzioni ibride metallo-composito realizzate con la tecnica co-cured, cioè incollando i materiali con la stessa resina adoperata per la manifattura del laminato composito. E’ stata studiata in particolare la giunzione fra alluminio e composito in fibra di vetro (Al/GFRP), accoppiamento che trova applicazioni in svariati ambiti del settore dei trasporti navali e terrestri. Sono stati analizzati giunti a semplice sovrapposizione (GSS) e a doppia sovrapposizione (GDS) sottoposti a carichi statici e di fatica. Tramite analisi numeriche FEM nonché prove sperimentali eseguite variando la lunghezza di sovrapposizione del giunto, si è indagato sul crite…

Advanced Techniques for Design and Manufacturing in Marine Engineering

Modern engineering design processes are driven by the extensive use of numerical simulations, and naval architecture as well as ocean engineering are no exception. Structural design or fluid dynamic performance evaluation can only be carried out by means of several dedicated pieces of software. Classical naval design methodology can take advantage of the integration of these pieces of software, giving rise to more robust design in terms of shape, structural and hydrodynamic performances, and manufacturing processes. This Special Issue (SI) on “Advanced Techniques for Design and Manufacturing in Marine Engineering”, published in the Journal of Marine Science and Engineering, aimed to invite …

Mechanical behavior of a sandwich with corrugated GRP core: numerical modeling and experimental validation

In this work the mechanical behaviour of a core reinforced composite sandwich structure is studied. The sandwich employs a Glass Reinforced Polymer (GRP) orthotropic material for both the two external skins and the inner core web. In particular, the core is designed in order to cooperate with the GRP skins in membrane and flexural properties by means of the addition of a corrugated laminate into the foam core. An analytical model has been developed to replace a unit cell of this structure with an orthotropic equivalent thick plate that reproduces the in plane and out of plane behaviour of the original geometry. Different validation procedures have been implemented to verify the quality of t…

Improving the Downwind Sail Design Process by Means of a Novel FSI Approach

The process of designing a sail can be a challenging task because of the difficulties in predicting the real aerodynamic performance. This is especially true in the case of downwind sails, where the evaluation of the real shapes and aerodynamic forces can be very complex because of turbulent and detached flows and the high-deformable behavior of structures. Of course, numerical methods are very useful and reliable tools to investigate sail performances, and their use, also as a result of the exponential growth of computational resources at a very low cost, is spreading more and more, even in not highly competitive fields. This paper presents a new methodology to support sail designers in ev…

A SIMULTANEOUS ENGINEERING APPROACH TO THE YACHT DESIGN

The authors describe the approach applied to the design and manufacturing of a 15” dinghy which will challenge other similar sailing boats in fleet regattas. The Simultaneous Engineering approach appears to be the most powerful instrument since it permits to keep under control many variables simultaneously and then to reduce the Time To Market. Starting from regatta rules and limitations, the hull shape has been chosen and then modelled with a parametric CAD software. Such a model has been managed in order to be suitable for both FEM (Finite Element Method) and CFD (Computational Fluid Dynamics) analyses.

Numerical analysis of composite plates with multiple delaminations subjected to uniaxial buckling load

Abstract In this paper the buckling and post-buckling behaviour of unidirectional and cross-ply composite laminated plates with multiple delaminations has been studied. Finite elements analyses have been performed, using a linear buckling model, based on the solution of the eigenvalues problem, and a non-linear one, based on an incremental-iterative method. With non-linear method large displacements have been taken into account and also contact constraints between sublaminates have been added to avoid their interpenetration. It has been found that both delamination length and position and stacking sequence of the plies influence the critical load of the plate; furthermore, linear and non-li…

ANALISI TRIDIMENSIONALE DI BUCKLING DI PIASTRE IN COMPOSITO CON DELAMINAZIONI MULTIPLE: APPLICAZIONE AI LAMINATI ANGLE-PLY

ANALISI NUMERICO-SPERIMENTALE DI SANDWICH IN COMPOSITO CON CORE CORRUGATO

Thermo-Mechanical Behaviour of Flax-Fibre Reinforced Epoxy Laminates for Industrial Applications

The present work describes the experimental mechanical characterisation of a natural flax fibre reinforced epoxy polymer composite. A commercial plain woven quasi-unidirectional flax fabric with spun-twisted yarns is employed in particular, as well as unidirectional composite panels manufactured with three techniques: hand-lay-up, vacuum bagging and resin infusion. The stiffness and strength behaviours are investigated under both monotonic and low-cycle fatigue loadings. The analysed material has, in particular, shown a typical bilinear behaviour under pure traction, with a knee yield point occurring at a rather low stress value, after which the material tensile stiffness is significantly r…

Simulation of Fatigue Delamination Growth in Composites with Different Mode Mixtures

A numerical model, obtained by implementing a cyclic damage model in the framework of an interface element, is here proposed to reproduce the crack growth in laminated composites subjected to cyclically repeated loads. This model, which differs from the few studies in the literature on the topic, applies not only to single fracture modes but also to mixed modes, and to constant or variable crack growth rates. The applied load (in terms of force or displacement) is assumed to oscillate between a minimum and a maximum constant value. The Paris curve can be reproduced with accuracy once some parameters in the numerical model are tuned with experiments. These parameters are preliminarily found…

Experimental Tests of Fatigue Induced Delamination in Gfrp and Cfrp Laminates

This work deals with the experimental analysis of the delamination phenomena in various composite materials under different loading conditions. Quasi-static and fatigue tests are performed on specimens made of glass-fibre reinforced plastic (GFRP) and carbon-fibre reinforced plastic (CFRP). In particular, under both quasi-static and fatigue loading, single fracture modes I and II (using standard DCB and ENF test configurations) and mixed modes I+II (using the MMB test configuration) with several mode mixtures, have been analysed. Further experiments of delamination growth with mode mixture that varies with the crack length, will be performed.

Mechanical Behaviour of a Green Sandwich Made of Flax Reinforced Polymer Facings and Cork Core

Abstract This work investigates the flexural behavior of a composite sandwich made of flax fibers reinforced skin facings and an agglomerated cork core, to be employed as an eco-friendly solution for the making of structural components of small sailing boats. An experimental mechanical characterization of the strength and stiffness flexural behavior of the proposed sandwich is carried out, providing a comparison of performances from three implemented assembling techniques: hand-lay-up, vacuum bagging and resin infusion. Sandwich beams have been tested under three point bending (TPB) at various span lengths. A procedure is also proposed and implemented to consider the potential influence of …

Biomechanical comparison between the modified rolling-hitch and the modified finger-trap suture techniques

Purpose: The purpose of this study was to characterize the biomechanical effect of two grasping suture techniques used during ligament reconstruction: the modified rolling-hitch (MRH) and the modified finger-trap (MFT). Methods: Flexor profundus tendons were harvested from fresh pig hind-leg trotters. Each specimen was mounted on an electro-mechanic universal testing machine (Instron 3367). In half of all tendons (15 specimens), the suture was passed around the tendon following the MRH knot (Group 1). In the remaining half of all tendons (15 specimens), the suture was passed over a distance of 30 mm according to the MFT suture technique (Group 2). As per standard intra-operative technique, …

Contact between the components of a knee prosthesis: numerical and experimental study

The aim of this work is the analysis of the contact area in a knee prosthesis using two different approaches. In particular, the interface between the femoral component and the polyethylene insert has been studied both numerically and experimentally. The interest in studying the contact area is related to the fact that the wear of the polyethylene insert, due to the high contact pressures, represents one of the major causes of failure of the total knee prosthesis. The possibility to evaluate the contact area at different loads and mutual position between femur and tibia is, therefore, of fundamental importance to study the service life of a prosthesis and to improve its performance. The fin…

Interlaminar fracture toughness behavior of electron-beam cured carbon-fiber reinforced epoxy-resin composites

The work describes the preparation and physical-mechanical characterization of unidirectional CFRP panels manufactured by an electron beam curing technique. Delamination fracture toughness in Mode I and II is investigated in order to evaluate the influence of fiber–matrix adhesion strength, matrix toughness and matrix crosslinking density as determined by the radiation curing process. A matrix system comprising a DGEBA epoxy monomer and an initiator of cationic polymerization have been used, with one batch of resin mixed with a PES monomer in order to enhance matrix toughness. Curing was achieved with a pulsed 10 MeV Electron Beam accelerator. Thermally cured composite systems have also bee…

Numerical study of the components positioning influence on the stability of a reverse shoulder prosthesis

Aim of this paper is to setup a novel procedure able to analyze performances of a reverse shoulder prosthesis when different geometrical configurations are assumed. Nowadays, such a prosthesis is widely used but, because of its novelty, data in literature give poor information about performances and limits to its applicability. The activity has been divided into the following steps. At the beginning the shape of the prosthesis has been digitally acquired via a 3D scanner. Then, CAD models of all prosthetic components have been geometrically optimized in a way to obtain final entities suitable for numerical simulations. After that, CAD assemblies have been created between prosthetic componen…

Radiation curing of carbon fibre composites

Epoxy/carbon fibre reinforced composites were produced by means of e-beam irradiation through a pulsed 10 MeV electron beam accelerator. The matrix consisted of a difunctional epoxy monomer (DGEBA) and an initiator of cationic polymerisation, while the reinforcement was a unidirectional high modulus carbon fibre fabric. Dynamic mechanical thermal analysis was carried out in order to determine the cross-linking degree. The analysis pointed out a nonuniformity in the cross-linking degree of the e-beam cured panels, with the formation of clusters at low Tg (glass transition temperature) and clusters at high Tg. An out-of-mould post irradiation thermal treatment on e-beam cured samples provides…

ANALISI STATICA E A FATICA DI GIUNZIONI IBRIDE CO-CURED METALLO COMPOSITO A SEMPLICE E A DOPPIA SOVRAPPOSIZIONE

Obiettivo di questo studio è l’analisi delle giunzioni ibride metallo-composito realizzate con la tecnica co-cured, cioè incollando i materiali con la stessa resina adoperata per la manifattura del laminato composito. E’ stata studiata in particolare la giunzione fra alluminio e laminato in fibra di vetro/resina epossidica (Al/GFRP), accoppiamento che trova applicazioni in svariati ambiti del settore trasporti. Le geometrie analizzate sono quella della giunzione a semplice sovrapposizione (Single Lap Joint) e a doppia sovrapposizione (Double Lap Joint), per confrontarne il diverso comportamento sotto l’applicazione di carichi monotoni e ripetuti ciclicamente. L’analisi è stata affrontata ad…

Numerical simulation of fatigue-driven delamination using interface elements

This paper presents a computational technique for the prediction of fatigue-driven delamination growth in composite materials. The interface element, which has been extensively applied to predict delamination growth due to static loading, has been modified to incorporate the effects of cyclic loading. Using a damage mechanics formulation, the constitutive law for the interface element has been extended by incorporating a modified version of a continuum fatigue damage model. The paper presents details of the fatigue degradation strategy and examples of the predicted fatigue delamination growth in mode I, mode II and mixed mode I/II are presented to demonstrate that the numerical model mimics…

Refitting of an eco-friendly sailing yacht: numerical prediction and experimental validation

A 4.60 m sailing yacht, made with a flax fiber composite and wood, has been refitted with the aim of hull weight reduction and performance improvement during regattas. The first objective was obtained with a lightening of internal hull reinforcements while the second one with a reduction of the maximum beam, in order to minimize the longitudinal moment of inertia. The refitting was first simulated via CAD-FEM interaction to establish the feasibility of the procedure and to verify the structural integrity. The resulting hull was then instrumented with strain gauges and tested under typical rigging and sailing conditions. Results obtained by the numerical modeling and measured from experiment…

A New ESO-Based Method to Find the Optimal Topology of Structures Subject to Multiple Load Conditions

In the field of topology optimization problems, the Evolutionary Structural Optimization (ESO) method is one of the most popular and easy to use. When dealing with problems of reasonable difficulty, the ESO method is able to give very good results in reduced times and with a limited request of computational resources. Generally, main applications of this method are addressed to the definition of the optimal topology of a component subjected to a single load condition. In this work, a new methodology, based on the ESO approach, is introduced for the study of the optimal topology of a component subjected to multiple load conditions. The new procedure, entirely developed in the APDL programmin…

Mode I fracture toughness behavior of hydro-thermally aged carbon fibre reinforced DGEBA-HHPA-PES systems

In this work the Mode I fracture toughness behavior of unidirectional CFRP laminates is investigated by means of Double Cantilever Beam (DCB) tests. The composite samples were manufactured by thermal curing after impregnation of a Carbon fabric with a DGEBA epoxy and anhydride HHPA curing agent. One resin batch was also mixed with a PES thermoplastic monomer to enhance the matrix toughness. Two lots of samples, toughened and un-toughened, were then left to soak in hot water to achieve various degrees of aging. The influence of matrix toughening and hydrothermal aging on the delamination behavior of the composite have then been assessed and correlated with characterization data from Dynamic …

EXPERIMENTAL TESTS OF FATIGUE INDUCED DELAMINATION IN GFRP LAMINATES

Fatigue delamination experiments on GFRP and CFRP specimens under single and mixed fracture modes

This paper deals with the experimental analysis of the delamination phenomena in composite materials under different loading conditions. Quasi-static and fatigue tests are performed on specimens made of glass-fibre (GFRP) and carbon-fibre (CFRP) reinforced plastic. In particular, experiments have been carried out under single fracture modes I and II (using standard DCB and ENF test configurations) and mixed modes I+II (using the MMB test configuration) with several mode mixtures. Results obtained for the two materials have been compared paying attention on the relationship between the parameters that describe the fatigue behaviour and the mode mixture acting during the crack propagation. © …

Topological optimization of a structural naval component manufactured in FDM

In this paper, a topological optimization procedure has been applied on a real component of the deck of a sailing multi-hull in order to find the internal shape that best save the material used in the manufacturing process without a relevant loss of structural rigidity. The multi-hull boat is a 16 feet length catamaran equipped with an asymmetric foil on both centerboards and with a symmetric foil on both rudders. The task of the analyzed object is to act as a cylindrical support for the screw that drives the rotation of the centerboard. The process adopted to manufacture this object is the Fused Deposition Modeling (FDM) technique, because of its high versatility and its relative low-cost …

A continuum damage model to simulate failure in composite plates under uniaxial compression

Experimental investigations and numerical simulations are performed in order to numerically predict the buckling behaviour of thin composite laminated specimens. Experiments are aimed at two objectives: the first is to completely characterize the carbon/epoxy material under simple loading configurations, the second is to test this material in buckling and post-buckling situations. The data collected with the first campaign of experiments are used to obtain the strength parameters required to define a damage model based on the failure theory by Tsai-Wu. This model is implemented in a Finite Element (FE) code and numerical simulations of buckling are executed for unidirectional and cross-ply …

Modal and Structural FEM Analysis of a 50 ft Pleasure Yacht

In this paper a structural Finite Element analysis of a 50 ft pleasure vessel is presented. The study is performed under different loads conditions: modal analyses have been done in order to find the natural frequencies of the vessel, structural analyses to verify the strength of the vessel to design loads. The design loads for the vessel considered are computed according to RINA rules for the construction and classification of pleasure vessels [1]. Two different composites are used for the lamination: one is a monolithic sequence of short fibre and balanced glass lamina, used for the bottom of the vessel and for structural reinforcements, the other is a sandwich made of glass fibre composi…

Yacht performance monitoring in real sailing conditions

Abstract In this paper a multi-method approach is used to setup and validate a monitoring system applied to a small sailing boat during real sailing conditions. This monitoring system is able to transform the data coming from some typical devices installed on board into information about the deformed state of the boat. GPS, Wind Data Logger and cameras have been installed on the boat to measure its route and speed, the apparent wind velocity and direction and the positions of the crew members. These data are processed to determine the equilibrium of the boat and estimate the loads applied on it. Then, a CAD/FEM model calculates the effects of these loads on the boat shape. The resulting def…

3D buckling analysis of multidelaminated composite specimens

The behaviour of thin composite laminates (unidirectional, cross-ply and angle-ply) under compressive loads has been examined in cases where multiple delaminations are present. The problem is solved using the Finite Element Method (FEM) both with linear analyses, based on the eigenvalues research problem, and with nonlinear analyses, based on incremental-iterative procedures. In particular, the role of the delamination length, of the angle of the plies and of the stacking sequence on the critical load is investigated. Results are compared with those found in literature derived from experimental or numerical 2D analyses.

A multi-technique simultaneous approach for the design of a sailing yacht

In this paper, most significant steps involved during the whole process of designing a sailing yacht are outlined. In particular, a novel simultaneous approach has been proposed to optimize the design process of a sailing yacht. Analytical resistance prediction models are simultaneously used with CAD systems and computational fluid dynamics tools to find, in the more effective way, the best solution for the chosen design conditions. As a general rule, in fact, once the target point has been decided, task of the designer is the definition of those systems of aerodynamic and hydrodynamic forces that are in equilibrium when the boat sails at its target. Unfortunately, a multi-purpose yacht doe…

Redesign of a Reverse Shoulder Prosthesis: Kinematic and Mechanical Study

In this work a commercial reverse shoulder prosthesis has been redesigned to improve performances in terms of range of movements of the implant and stability to dislocation. A kinematic and mechanic study has been performed using a realistic solid model of the prothesised shoulder: in particular, all the components of the prosthesis have been acquired via a 3D laser scanner and inserted in a virtual humerus-glenoid system by reproducing the common surgical procedure. The final model has been used to measure the maximum angles of abduction and rotation of the arm and the shear forces that cause dislocation. Modifications proposed to the commercial prosthesis are: a different orientation of t…

Mode I fracture toughness behaviour of epoxy resincarbon fiber composites cured by ionising radiation

In this work Mode I fracture toughness behavior of Electron Beam cured unidirectional CFRP laminates is investigated by means of standardized Double Cantilever Beam (DCB) tests. A matrix system, comprising a DGEBA epoxy monomer and a typical initiator of cationic polymerization, was used and panel samples assembled by hand lay-up. Curing was achieved by 20 to 40 minutes irradiation on a pulsed 10 MeV Electron Beam accelerator. One batch of resin was also mixed with 10 phr of a PES thermoplastic monomer in order to enhance the matrix toughness. The influence of fibre-matrix adhesion, matrix toughening and matrix crosslinking density on the mode I delamination behavior have been investigated …

Parametric Hull Design with Rational Bézier Curves and Estimation of Performances

In this paper, a tool able to support the sailing yacht designer during the early stage of the design process has been developed. Cubic Rational Bézier curves have been selected to describe the main curves defining the hull of a sailing yacht. The adopted approach is based upon the definition of a set of parameters, say the length of waterline, the beam of the waterline, canoe body draft and some dimensionless coefficients according to the traditional way of the yacht designer. Some geometrical constraints imposed on the curves (e.g., continuity, endpoint angles, curvature) have been conceived aimed to avoid unreasonable shapes. These curves can be imported into any commercial Computer Aide…

DEVELOPMENTS OF A NUMERICAL METHOD TO SIMULATE FATIGUE DELAMONATION IN COMPOSITES

Finite element analysis of two total knee joint prostheses

Aim of this work is to compare two different total knee prostheses that differ mainly in the shape of the polyethylene (PE) component inserted between the femoral and tibial plates. The best solution between them has been originally reshaped in order to reduce stress peaks. The study procedure has been divided into the following steps. First step is the digitalisation of the shape of the prostheses by means of a 3D laser scanner. The morphology of two prototypes of the prostheses has been acquired by elaborating multiple Moire fringe patterns projected on their surfaces. Second step consisted on the manipulation of these data in a CAD module, that is the interpolation of raw data into NURBS…

MIXED-MODE DELAMINATION TESTS ON COMPOSITES UNDER FATIGUE LOADS

Using FEM simulation to predict structural performances of a sailing dinghy

The use of finite element method (FEM) tools is proposed to investigate the structural response of an eco-sustainable sailing yacht to different loading conditions, typical of those acting during regattas. The boat is, in particular, a 4.60 m dinghy with the hull and the deck made of an hybrid flax–cork sandwich and internal reinforcements made of marine plywood. A preliminary activity has consisted in the refitting of an existing model in order to reduce the hull weight and to improve performances during manoeuvrings. These tasks have been interactively simulated in the virtual environment of the boat CAD model, where longitudinal and transversal reinforcements were enlightened and the m…

Parametric Hull Design with Rational Bézier Curves

AbstractIn this paper, a tool able to support the sailing yacht designer during the early stage of the design process has been developed. Quadratic and cubic Rational Bézier curves have been selected to describe the main curves defining the hull of a sailing yacht. The adopted approach is based upon the definition of a set of parameters, say the length of water line, the beam of the waterline, canoe body draft and some dimensionless coefficients according to the traditional way of the yacht designer. Some geometrical constraints imposed on the curves (e.g. continuity, endpoint angles) have been conceived aimed to avoid unreasonable shapes. These curves can be imported in any commercial CAD …

Designing the internal reinforcements of a sailing boat using a topology optimization approach

In naval design it is common practice to define an internal regular web frame made of longitudinal elements and transversal sections with the purpose of giving stiffness to the whole structure and, at the same time, promoting lightness. In this work, FEM simulation and Topology Optimization (TO) tools are implemented to present a different approach in placing the reinforcements inside the hull of a sailing dinghy. The methodology proposed in this paper considers as a starting point the volume inside the hull and the deck completely filled with material and the result after the simulations is a free form shape of the sailboat reinforcements. The TO procedure is based on two different input F…