A Research proposal

on

IMPERFECTION ANALYSIS ON AXIALLY COMPRESSED COMPOSITE

CYLINDRICAL SHELLS

By

MOHD SHAHROM BIN ISMAIL

Professional Excellence Division

Department of Polytechnic Education

Ministry Of Higher Education

 Table of Contents

Chapter 1 ................................................................................................................................ 1
1.1. Introduction ............................................................................................................. 1
1.2. Background and rationale ........................................................................................ 1
1.2.1. Research objectives .......................................................................................... 5
1.3. Research Problem and Hypotheses ......................................................................... 6
1.3.1. Statement of Research Problem ....................................................................... 6
1.3.2. Research Questions .......................................................................................... 6
1.3.3. Research Hypotheses ....................................................................................... 6
1.4. Significant of Findings ............................................................................................ 7
Chapter 2 ................................................................................................................................ 8
2.1. Introduction ............................................................................................................. 8
2.1.1. Dependent variables ......................................................................................... 8
2.1.2. Independent variables....................................................................................... 9
2.2. Conceptual model .................................................................................................. 10
2.3. Scope of study ....................................................................................................... 11
Chapter 3 .............................................................................................................................. 12
3.1. Introduction ........................................................................................................... 12
3.2. Research design ..................................................................................................... 12
3.3. Sampling design .................................................................................................... 15
3.4. Research Equipment .............................................................................................. 15
3.5. Data collection ....................................................................................................... 15
3.6. Data analysis .......................................................................................................... 15
Chapter 4 .............................................................................................................................. 16
4.1. Introduction ........................................................................................................... 16
4.2. Research Schedule ................................................................................................. 16
References ............................................................................................................................ 17
 Chapter 1

1.1. Introduction

The buckling problem of shell structures continuously attracts numbers of engineers in

finding the appropriate solution. Certainly there are few aspects that need to be addressed,

such as, types of load, i.e. load eccentricity, shells geometry, i.e. initial imperfections,

material characteristics and variety of boundary conditions. Stiffened cylindrical shell

structures are common panels that have been widely used in the marine industry,

predominantly in offshore structures. Commonly, offshore structure exposedwith initial

imperfection during the fabrication stage or shells exploitation, i.e. existence of permanent

dent during installation. With the present of initial geometry imperfections and exposure

tothe extreme loading condition during service, the structural integritybecomes a major

issue. To date, thereis no known efficient guideline for modeling imperfections ofthe

stiffenedcylindricalshellavailable. For that reason, acomprehensive understanding in shell

buckling and its imperfectionare necessary to be revised and updated.

1.2. Background and rationale

Since the first aircraft invented by Orville and Wilbur Wright brothers, the specific

requirements to compensate the power to weight ratio always sought for updates.

Eventually, with more advancement of technology, the selection of material with the aim

for lighter structures often becomes a primary preference due to its prospect of inexpensive

production and operational cost. The subsequent lower structural weight contributes to

reducing the fuel consumption and also gives a positive effect on the environment. To date,

rapid developments in the aerospace manufacturing technology encourage the

engineers/designers to seek more suitable candidate materials that demonstrate excellent

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improvements in weight, stiffness and stability. These criteria are found to be associated

with advanced composite materials, where it offers an outstanding ability in reducing the

structural weight while increasing its strength.

By far, the use of composite material is expected to be in line with the demand

made by most of the European aircraft industry to mitigate the development and operating

cost near to 20-50% in the future (Degenhardt et al., 2014). Nonetheless, the challenge is

answered by the growing numbers of composite material, particularly carbon fibre

reinforced plastic (CFRP) in the current design of Dreamliner 787 and Airbus A350, as it

contains at least 50% of the entire structure. Evidently, the growth in the use of CFRP

composites increased dramatically from 15% in 1990 (A320) to over than 50% in 2010

(A380) specifically for airframe structures (Baker, Baker, & Kelly, 2004). Hence, the trend

clearly represents the potential of fibre-reinforced polymer (FRP) matrix composites in

offering an alternate replacement of high-strength isotropic materials. The overall

application of CFRP material that covers of Boeing 787 Dreamliner structure and its

componentSeveral approaches have been developed and become a tool in estimating

structural ultimate load carrying capacity.

It is well known that most of aerospace/aircraft structures are generally designed in

the form of thin walled structures. Therefore issues that associated with buckling,

instability and collapse constantly take place in the relevant design as its tendency prone to

buckling. To be more specific, buckling load of the thin walled cylinder structure under

axial compression is a classical structural problem. In practice, during operation hour, flight

loads and internal/external pressure are present in typical lightweight structure involving

commercial aircraft or launch vehicle fuel tank. In certain condition, some of these loads

may act pre-dominantly as a compressive load remarks to its structural weight and pay-load

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during operational session. Therefore, investigation on characterizing the structural

buckling event is essential to carry out, to guarantee its safety and assurances.

Typical cylindrical shell structures imposed with an issue in predicting the buckling

load, as it gives relatively large differences between experimental and theoretical. This

condition can be associated with the presence of imperfection in real structures. In detail,

the structure imperfection can be divided into three categories: (1) geometrical (2) material

and (3) load-boundary condition prior to buckling event. Firstly, the geometrical

imperfection relates to the corresponding miss-shaped, dimension and geometrical

structures themselves. Secondly, the material factor can be described on its differences of

its properties such as elastic modulus, yield properties and strain-rate further exemplified

by isotropic material. In the view of material complexity, composite material by far would

present an influence in material nonlinearity. As a lot of considerable factors such as fibre-

angle misalignment, local ply-gaps and stacking sequence would always carry a strong

effect on structural imperfection.

Lastly, the load-boundary condition continuously brings a strong effect toward

imperfection. This is illustrated during the buckling event, where the real buckling

boundary condition is hardly to quantify. It should note that during the compression event,

the direction of compressive load is not always perpendicular to the cylinder itself.

Moreover, the corresponding event leads to unevenness in load distribution along the

cylinder circumferential whereas the bending effect may take place in the whole buckling

process.

In particular, with regard to the aerospace structures, prediction of knockdown factor

remains highly dependent on the empirical guideline from NASA SP-8007 (1968) that

uses the conservative lower bound curve. Despite of its success, most of European

counterpart commonly used the European Convention for Construction Steelwork, ECCS

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(1988) in designing thin-walled structure. Indeed, the subsequent ECCS guideline is

generally originated from NASA SP-8007 itself. Unfortunately, the guideline is mainly

intended for the isotropic materials, and less information corresponding to the composite

material is described. Simultaneously, the cylindrical structures imperfection is not well

defined, thus leads to underestimating of knockdown factor and buckling load. It is

essential to note, that the derived knockdown factor is a normalized value between

experimental buckling load with linear bifurcation ones ( = Pexperiment/Plinear).

So far, prior to designing the composite cylinder, NASA SP-8007 offers in using

the effective thickness, teff. The effective thickness can be associated in composite stiff and

bending terms. Unfortunately the effective thickness, do not represent the real structural

formation. Therefore, to reduce the structural weight, the use of effective thickness, teff is

seemed to be unpractical. In particular, Arbelo et al. (2014) reported the use of NASA SP-

8007 (1968) in the design of the European Ariane-5 rocket launcher. Eventually, even

though the rocket has an outstanding performance, the structural design seemed to be

considerably conservative, resulting in exceptionally higher costs in the production and

operation (Castro et al., 2014; Haynie & Hilburger, 2010).

With such limitations, NASA SP-8007 does not take into account of full material

potential. This can be relate in the prediction of knockdown factor that linked to its lower

bound curve (Arbelo et al., 2013).By far, the consequent approach direct to excessively

conservative designs on estimating cylinder buckling load (Arbocz & Starnes Jr, 2002;

Degenhardt et al., 2010; Hilburger et al., 2006; Hhne et al., 2008). At the same time,

ECCS guideline also leads to a more conservative design as it recommended on using extra

safety factor which is nearly 1.5 times greater than NASA SP-8007 standard. Apparently,

the need for a new precise and reliable design guideline for imperfection sensitive

composite structures is highly needed. By having such guideline, a better prospect of

4
allowing a significant reduction of structural weight and design can be established in the

future.

1.2.1. Research objectives

The primary aim of the study was to generate research and design information on the

behaviour of buckling and postbuckling mechanism and the influence of imperfection on

cylindrical shell under axial compressive loading. The outcomes of the study would

facilitate and extend the application of composite cylinder shell in future guideline of

aerospace design.

The subsequent aims of the study are:

1. To develop a FE model and identify the reliable imperfection technique that

is suitable for the preliminary design process of axially compressed

cylinders.

2. To validate the FE model against the available experimental results in

literatures.

3. To extend the validation work using the SPLA imperfection technique by

considering stiffened cylinder structure.

4. To perform a parametric study in order to show the ability of each method in

designing cylindrical shell by considering variation of materials and

geometries.

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1.3. Research Problem and Hypotheses

1.3.1. Statement of Research Problem

How could the occurrence of axially-compressed composite cylinder be quantified for

stability tolerance and reliability of the aerospace/aircarft structural members?

1.3.2. Research Questions

1. What are dominant buckling failure mechanisms of axially-compressed composite

cylinder shell?

2. What are available and accurate imperfection models/techniques that account the

real initial geometric imperfection/dent of composite cylinder shell?

3. How accurate the recent imperfection models/techniques in validating the

composite cylinder buckling nature including its strength and failure mechanism?

4. How strong the composite cylinder shells with large stiffeners in resisting the

applied load before it could reach failure?

5. What design rules and conclusions can be withdrawn considering the latest

imperfection model/technique and its affect with such structures accounting their

geometrical variations?

1.3.3. Research Hypotheses

As discussed in section 1.2, it can be remarked that there is still a lack of information and

effective guidelines reported in literature for introducing an imperfection in the stiffened

cylindrical shells under combine loading, i.e. axial compression and pressurized loads.

Thus, relevant updates are always sought to address the new design challenges that suit the

current technology demands. The present study propose to evaluate the response of the

6
composite cylindrical shells subjected to axially compressed by utilizing the SPLA and SID

method through finite element analysis. The propose works are purely numerical, and it

verifies the recently develop imperfection models/technique with the published

experimental data given in (Haim Abramovich et al., 1988; Kwok, 1991; Walker et al.,

1982). The contribution of the study covers the influence of initial imperfection in terms of

its depth, magnitude, size and location to the corresponded shells buckling

strength.Inclusive recommendations are also can be introduced by examining the buckling

resistant of stiffened cylinders in accounting their geometrical variations.

1.4. Significant of Findings

The findings are expected to give some updates to those who are working in the area of

designing the shell structures with appropriately addressed its relevant imperfection. A new

efficient design approach is expected to come up with possibilities for reducing the design

cost and structural weight.

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 Chapter 2

2.1. Introduction

This chapter describes the aspect and dimensions of the research problem in

adequate detail.

2.1.1. Dependent variables

The dependent variables are described sufficiently in Table 2.1.

Table 2.1: Type of dependent variables and indicators.

Type
Buckling failure mechanism
The extent of the buckling mode due to applied
load leading to structural failure and instability.
Indicators
a) Mechanisms - types of buckle mode
quantified by the number of waves around
the structure circumferential and axial.
b) Evolution - characteristic of the continuous
buckling wave with the increase of load.
c) Damage/failure - terminal value once
reaches the material yield criteria.

Structural load carrying capacity a) Loading history - characteristic of the

The strength of designingstructures that carries reaction force and structural displacement.
the subjected load. b) Buckling load - characterized by the peak of
the reaction force during the buckling event.
c) Local snap through - characterized by the
drop of the reaction force once the structure
exceeds the initial buckle.
Material a) Stress - terminal value of the material failure
The material characteristic in Elasto-plastic once reach the yield stress/plasticity
regime. condition.
b) Strain - terminal value of the material failure
once reach 2% of plastic strain.

8
2.1.2. Independent variables

The independent variables are described sufficiently in Table 2.2.

Table 2.2: Type of independent variables and its indicators.

Type Indicators
Stiffened cylinder geometry a) Geometry - sizes of the cylinder and
Largely influence the structural buckling load. stiffener profiledefine as (R, t, L, b, hand N)
shown in Figure 2.1.
Structural imperfection a) Term - the imperfections are defined as
Largely influence the structural buckling load. (Ppeturb and a/t).
b) Geometry varied the size, depth, width and
location.
Material imperfection a) Elastic (E) - the value of the material elastic
Moderately influence the structural buckling modulus is varied by 5%.
load. b) Yield (yield) - the value of the material yield
stress is varied by 5%.
Loading condition a) Eccentric Load (e) impliedby offsetting
Moderately influence the structural buckling the axial loadfrom the center of the cylinder
load. quantified as (e/R).
Boundary condition a) Cylinder holding/grip condition - implied
Moderately influence the structural buckling the type of boundary condition (CL, SS3 and
load. SS4)

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Figure 2.1: Example of stiffened cylinder with (a) ring-stiffened (b) stringer-stiffened

profiles.

2.2. Conceptual model

The interactions among dependent and independent variables of the research (cause-

andeffect) are described in Table 2.2.

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2.3. Scope of study

The scope of study covers the followings:

1. Stiffened cylinder isotropic structure will be used as representative model.

2. The validation work will involve in comparing the experimental data taken from

open literatures with finite element model.

3. Establish guideline/code will be used as well for verification proposes.

4. The SPLA, SID and recommended guideline/codes will be used tomodel the

imperfection via the finite element environment.

5. The research covers the stiffened cylinder subjected to axially compressed and

externally pressured loads as well as a combination of both.

6. Finite element software, Abaqus Ver. 6.10 or newer will be used as a tool to

conduct research whilst the excel spreadsheet to store data.

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 Chapter 3

3.1. Introduction

The methodology of the proposed research, including operational framework, sampling

design, required research equipment, data collection and analysis is described in adequate

detail in this chapter.

3.2. Research design

The operational framework of the proposed research is describe below. Each major activity

is briefly described as follows:

Task A: Reviewing literatures

Conduct comprehensive and collective survey on the buckling performance of the

stiffened-cylinder structure and its imperfection subjected to combine/pure loading

condition.

Task B: Development of FE model

Numerical model development is aimed to produce a general purpose finite element model

for estimating the load carrying capacity of the particular stiffened-cylinder shell under

expected loading condition. The scope covers:

a) Reviewing and updating the existing imperfection techniques to be implemented via

finite element environment in order to establish the structural imperfection.

b) Extraction of model parameters/properties/profiles from the test data.

c) The validation of each material model by comparing the FE prediction with taken

experimental data, i.e. buckling load and recommended design guideline/code.

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Task C: Validation testing program

The validation testing program consists of quasi-static tests of the stiffened cylinder under

combined loading to buckling failure:

a) Implementing the recommendation/code to find the adequate design of the stiffened

cylindrical shell.

b) Purely axial compression or externally pressured loading to search for the adequate

load carrying capacity and imperfection values.

c) The combination of axially compressed and externally pressured loads to establish

an interaction curve for design recommendation purpose.

The dimension and material properties of stiffened cylindrical shells used for validation

study will be established numerically from the following literatures.

Item Verification model Authors

a) Type: Ring-stiffened cylinder (Kwok, 1991)

Models: R1, C4, C5, C6, C9, C10, C11, C12 and R2
Geometry: R/t = 267, L/R = 0.25 and h/b = 8
Material properties: E = 520 GPa, yield= 294 MPa and
= 0.29
b) Type: Stringer-stiffened cylinder (H. Abramovich et al., 1988)
Models: DUD-8 and DUD-10
Geometry: R/t = 267, L/R = 0.25 and h/b = 8
Material properties: E = 70 GPa, yield= 384 MPa and
= 0.3
c) Type: Ring-stiffened cylinder (Walker et al., 1982)
Models: S3, S4
Geometry: R/t = 267, L/R = 0.25 and h/b = 8
Material properties: E = 520 GPa, yield= 294 MPa and
= 0.29

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Task D: The mechanical parametric program
The mechanical parametric program involves in varying the parameters that suspected to
affect the structural load carrying capacity and imperfection. The parameters cover:
Item Parametric study description
a) Type: Ring/stringer-stiffened cylinder
Geometry: R/t = 474 andL/R = 108.3
Varying: L/R = 0.25-3
Stiffeners location: inside/outside
Material properties: E = 280 GPa, yield= 524 MPa
and = 0.29
b) Type: Ring/stringer-stiffened cylinder
Geometry: R/t = 474 andL/R = 108.3
Varying: As/st and Ar/st = 0.5 - 8
e/t = 3.5 - 16
Stiffeners location: inside/outside
Material properties: E = 280 GPa, yield= 524 MPa
and = 0.29
c) Type: Ring/stringer-stiffened cylinder
Geometry: R/t = 474 andL/R = 108.3
Varying: E andyield = 5%
Stiffeners location: inside/outside
Material properties: E = 280 GPa, yield= 524 MPa
and = 0.29
d) Type: Ring/stringer-stiffened cylinder
Geometry: R/t = 474 andL/R = 108.3
Varying: eload/R = 0 - 5
14
Justification
1. Does the imperfection
amplitude changes due to the
increase of cylinder length?
2. Does the location of the
stiffeners gives much
influence on the imperfection
amplitude?
1. Check the effect of stiffener
size and eccentricity heavily
influence the imperfection
amplitude.
2. Check if the stiffeners buckle
or not. If not, then the SPLA
seems not valid and must
execute MPLA (multiple
perturbation load approach)
to ensure the structure
buckle.
Does material properties affect
the structural buckling load.
Does the load transfer eccentric
affects the structural buckling
load.
 Stiffeners location: inside/outside
Material properties: E = 280 GPa, yield= 524 MPa
and = 0.29

Task E: Development of design rules and recommendations

Develope the design rules on thebuckling resistant of stiffened-cylinderin plastic region

considering the initial imperfection models/techniques under combine load interaction.

3.3. Sampling design

The stiffened-cylinder FE model will be develop accordingly.

3.4. Research Equipment

Testing equipment and facilities required for the proposed research are listed in Table 1.

Table 1: List of equipment/facilities and their availabilities

Abaqus finite element software package HPC Lab, users Laptop

High performance computing facilities HPC computers Lab, engineering Faculty,

UTeM, Malacca

3.5. Data collection

Load and displacement data pairs will be recorded using the available Abaqus finite

element environment and Excel spreadsheet.

3.6. Data analysis

Measured data will be processed and analyzed using standard Excel spreadsheet.

15
 Chapter 4

4.1. Introduction

The research plan and milestones are described in this chapter.

4.2. Research Schedule

The proposed duration of the research is 36 months, from September 2017 to August 2020.

The research plan and milestones are shown in Table 4.1.

Table 4.1: Propose project Gantt Chart.

Q1 Q2 Q3 Q4 Q5 Q6 Q7 Q8 Q9
Activities Sept Jan - Mei - Sept - Jan - Mei - Sept - Jan - Mei -
Dis April August Dis April August Dis April August
2017 2018 2018 2018 2019 2019 2019 2020 2020

Task A:
Reviewing
literatures

Task B:
Development of M1
FE model

Task C:
Validation testing M2
program

Task D:
The mechanical
M3
parametric
program
Task E:
Development of
M4
design rules and
recommendations

Task F:
Thesis/report M5
writing

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MILESTONES

ID Milestones description

M1 Completion of FE model

M2 Submission and presentation forconference proceeding

M3 Submission offirst manuscript for ISI publication

M4 Submission of second manuscript for ISI publication

M5 Submission of thesis

References

Abramovich, H., Weller, T., & Singer, J. (1988). Effect of sequence of combined loading
on buckling of stiffened shells. Experimental Mechanics, 28(1), 113.
http://doi.org/10.1007/BF02328988
Abramovich, H., Weller, T., & Singer, J. (1988). Effect of sequence of combined loading
on buckling of stiffened shells. Experimental Mechanics, 28(1), 113.
http://doi.org/10.1007/BF02328988
Arbelo, M. A., Degenhardt, R., Castro, S. G. P., & Zimmermann, R. (2014). Numerical
characterization of imperfection sensitive composite structures. Composite Structures,
108, 295303. http://doi.org/10.1016/j.compstruct.2013.09.041
Arbelo, M. A., Zimmermann, R., & Castro, S. G. P. (2013). Comparison of new design
guidelines for composite. In Ninth International Conference on Composite Science
and Technology (pp. 96111). Sorrento, Italy.
Arbocz, J., & Starnes Jr, J. H. (2002). Future directions and challenges in shell stability
analysis. Thin-Walled Structures, 40(9), 729754. http://doi.org/10.1016/S0263-
8231(02)00024-1
Castro, S. G. P., Zimmermann, R., Arbelo, M. A., Khakimova, R., Hilburger, M. W., &
Degenhardt, R. (2014). Geometric imperfections and lower-bound methods used to
calculate knock-down factors for axially compressed composite cylindrical shells.
Thin-Walled Structures, 74, 118132.
Degenhardt, R., Kling, A., Bethge, A., Orf, J., Krger, L., Zimmermann, R., Calvi, A.
(2010). Investigations on imperfection sensitivity and deduction of improved knock-
down factors for unstiffened CFRP cylindrical shells. Composite Structures, 92(8),
19391946. http://doi.org/10.1016/j.compstruct.2009.12.014
ECCS. (1988). Buckling of steel shells: European recommendations. Buckling of Shells.
5th Ed. Brussels: European Convention for Constructional Steelwork, 384.
Haynie, W. T., & Hilburger, M. W. (2010). Comparison of Methods to Predict Lower
Bound Buckling Loads of Cylinders under Axial Compression. 51st
AIAA/ASME/ASCE/AHS/ASC Structures, Structural Dynamics, and Materials
Conference.
Hilburger, M. W., Nemeth, M. P., & Starnes, J. H. (2006). Shell Buckling Design Criteria

17
 Based on Manufacturing Imperfection Signatures. AIAA Journal, 44(3), 654663.
Hhne, C., Rolfes, R., Breitbach, E., & Temer, J. (2008). Robust design of composite
cylindrical shells under axial compression Simulation and validation. Thin-Walled
Structures, 46(79), 947962. Retrieved from
http://linkinghub.elsevier.com/retrieve/pii/S0263823108000438
Islam, A. B. M. S., Jameel, M., & Jumaat, M. Z. (2012). Oil and gas energy potential at
malaysian seabed and spar platform for deepwater installation. International Journal
of Green Energy, 9, 111120. http://doi.org/10.1080/15435075.2011.621493
Kwok, R. (1991). Mechanics of damaged thin-walled cylindrical shells. University of
Surrey, Guilford, Unpublished Phd Thesis.
Walker, A. C., Segal, Y., & McCall, S. (1982). The buckling of thin-walled ring-stiffened
steel shells. (E. Ramm, Ed.)In: Ramm E. (eds) Buckling of Shells. Berlin, Heidelberg:
Springer, Berlin, Heidelberg.
Weingarten, V. I., Seide, P., & Peterson, J. P. (1968). Buckling of thin-walled circular
cylinders. NASA SP-8007 Monograph.

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