Numerical modeling of adhesively bonded composite patch repair of cracked aluminum panels with concept of CZM and XFEM

Abstract

Application of composite patches in repair of damaged/aged aircraft structures is one of the most popular repairing methods in aerospace engineering. Since running experiments are difficult, time consuming, expensive, and also require high level of expertise, simulation of the behavior of the patch and also the faulty components after repair can assist designers and engineers in optimization of their designs. In this article, full-scale simulation of a damaged panel that is experimentally repaired with a composite patch will be considered using ABAQUS, a commercial finite element code. The crack growth process is modeled with the extended finite element method and the cohesive zone model (CZM) is used to model the progressive damage in the adhesive of the composite patch repair. Also, sensitivity analysis is performed on the CZM parameters and it is shown that the three parameters i.e. the shear toughness, maximum first shear traction, and penalty parameter for the elastic stiffness are important in the simulation of adhesively bonded composite patch repairs. The calibrated cohesive properties are successfully used to predict the response of the composite patch to the strengthened in damaged structure with considering the linear and nonlinear stage of failure process. The simulation results obtained in different stages have been verified with the existing experimental results.

Keywords

Composite patch repair extended finite element method cohesive zone model crack propagation optimization calculation of stress intensity factor

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