Hipper wrote: ↑Sat Jun 24, 2023 11:17 am
How easy is it to check for stress issues with CFRC and what experience is there compared to metals?
What would be the reason to choose CFRC as opposed to, say, titanium type designs? Cost? Weight?
The shape was apparently to enable more passengers to be accommodated.
One can use FEA on structural sections to predict stress fields but this relies on the accuracy of the material properties and the modelling used ( i.e. rubbish in rubbish out). FEA would apply equally well to any material so long as there is confidence in the measured material properties and its behaviour under tensile, compressive, shear modes of loading.
CFRC are used in aerospace applications because of their strength/weight ratio. They are very strong when put in tension. Obviously low weigh and high strength is very desirable in aerospace, F1, racing bicycles, etc.
The problem with CFRC is that when they are subjected to bending high "shear" stresses will develop within the cross-section of the structure. Shear stresses will generally be highest at the centre line through a wall section ( thickness). The CFRC structures are manufactured using continuous carbon fibre plies impregnated with resin and these are wound around a mandrel and cured to form the desired outer shape of the structure. Consequently the fibre plies will run parallel to each other - think of stacked fibres criss-crossing each other on stacked layers as the thickness of a structure is built up. The structure will be fine in tension because the strong carbon fibres will carry the load. However the composite will be weak in bending because you'll have a resin rich matrix between the fibres ( an analogy : in a wall section fibre plies are stacked like a deck of playing cards but between each card there is only the resin holding the structure together). When the composite is subjected to bending the resin bonding the fibres will be put under high shear stresses and ultimately at some critical shear stress will delaminate creating a crack in the resin between the fibres layers. The crack will grow in length as the bending ( compressive stresses) increases. So, summary CFRC strong in tension, weak in compression because it is the plastic resin that tries to carry the loads in compression.
Titanium alloy used in aerospace is based on Ti-6Al-4V. The alloy has very small, ( micron size) discrete precipitates in a Ti rich matrix. The precipitates act as "crack stoppers". So, should a crack start in a component made from this alloy it is quickly snuffed out because the precipitates are obstacles to the growth of a crack. Think of it as the crack having to deviate its path to get around the precipitate - it needs more energy to do that. The Ti-6Al-4V alloy has what is called a good fracture toughness ( good at stopping cracks growing).
Simple test for you to see the effect a small crack has on a structure. Get a plain A4 sheet of paper and hold it up in from of you - hand on each of the shorter sides as though you were looking in a mirror. Now, try pulling the paper sheet apart moving your hands apart.
Now repeat this but this time just put a small tear, about 10 mm length in the paper on the mid point of one of the long sides. Hold it up so the tear is on the top edge and try pulling the sheet again
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Sorry for the long explanation so late on a Saturday but - sat outside on a beautiful, warm evening drinking a nice Merlot.
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