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Numerical Methods and Modeling Applied for Composite Structures

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A special issue of Materials (ISSN 1996-1944). This special issue belongs to the section "Advanced Composites".

Deadline for manuscript submissions: closed (20 January 2025) | Viewed by 13713

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Dr. Pawel Wysmulski

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Department of Machine Design and Mechatronics, Faculty of Mechanical Engineering, Lublin University of Technology, 36 Nadbystrzycka St., 20-618 Lublin, Poland
Interests: thin-walled structures; laminates; buckling; critical state; finite element method; computational mechanics
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Dr. Katarzyna Falkowicz

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Guest Editor

Department of Machine Design and Mechatronics, Faculty of Mechanical Engineering, Lublin University of Technology, 36 Nadbystrzycka St., 20-618 Lublin, Poland
Interests: computational mechanics; stability; plate elements; composites; matrix couplings; FEM; thin-walled structures; linear and nonlinear analysis
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Dr. Patryk Rozylo

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Guest Editor

Faculty of Mechanical Engineering, Lublin University of Technology, Nadbystrzycka 36, 20-618 Lublin, Poland
Interests: buckling; post-buckling; failure; laminates; finite element method; numerical simulations; computational mechanics; thin-walled structures
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Special Issue Information

Dear Colleagues,

Designing modern structures with optimised strength and stiffness parameters requires the use of modern technologies. This applies in particular to high-tech aeronautical or automotive structures, in which the most beneficial solutions in terms of operation and durability are obtained, for example, by replacing previously used materials with modern composite materials. These primarily include polymer laminates reinforced with continuous fibres, most commonly carbon-fibre-reinforced plastics (CFRP) and glass-fibre-reinforced plastics (GFRP). Due to the very favourable mechanical properties of these materials in relation to their own weight, it has become possible to use fibre composites for carrier elements of thin-walled structures (e.g., covering reinforcement profiles). Laminates make it possible to create the mechanical properties of designed components in terms of their ability to carry the appropriate type of load. This characteristic makes it possible to achieve very advantageous construction designs; however, this requires the use of modern testing methods that enable the performance of the structure to be analysed over the full load range. The studies of composite structures known from the literature mostly focus on analytical and numerical considerations, usually conducted on structures with typical cross sections operating under ideal conditions, subjected to simple loading cases: compression, shear, or simple bending. Only to a limited extent are such considerations verified by experimental tests on real construction elements.

Dr. Pawel Wysmulski
Dr. Katarzyna Falkowicz
Dr. Patryk Rozylo
Guest Editors

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Keywords

laminates
CFRP
GFRP
buckling
stability
failure
crack damage
finite element method
numerical method

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Published Papers (11 papers)

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Research

26 pages, 9237 KiB

Open AccessArticle

Early Detection and Analysis of Cavity Defects in Concrete Columns Based on Infrared Thermography and Finite Element Analysis

by Fan Yang, Xianwang Zeng, Qilong Xia, Ligui Yang, Haonan Cai and Chongsheng Cheng

Materials 2025, 18(7), 1686; https://doi.org/10.3390/ma18071686 - 7 Apr 2025

Viewed by 510

Abstract

Concrete, known for its high strength, durability, and flexibility, is a core material in construction. However, defects such as voids and honeycombing often occur due to improper pouring or vibration, weakening the concrete’s strength and affecting its long-term performance. These defects typically require costly repairs. Therefore, timely identification and repair of such early defects is crucial for improving construction quality. This paper proposes a method for non-destructive detection of honeycomb defects in concrete using infrared thermography (IR) during the hydration stage. By analyzing the temperature differences between defect and non-defect areas based on the temperature distribution generated during hydration, defects can be detected. Furthermore, the study uses the COMSOL finite element model to explore the relationship between defect size, ambient temperature, formwork thickness, and thermal contrast. The results show that IR technology can effectively and reliably detect honeycomb defects, especially during the hydration phase. As a convenient and feasible non-destructive testing method, IR technology has significant potential for application and development in concrete defect detection. Full article

(This article belongs to the Special Issue Numerical Methods and Modeling Applied for Composite Structures)

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24 pages, 818 KiB

Open AccessArticle

Accelerating Multi-Objective Optimization of Composite Structures Using Multi-Fidelity Surrogate Models and Curriculum Learning

by Bartosz Miller and Leonard Ziemiański

Materials 2025, 18(7), 1469; https://doi.org/10.3390/ma18071469 - 26 Mar 2025

Viewed by 359

Abstract

The optimization of multilayer composite structures requires balancing mechanical performance, economic efficiency, and computational feasibility. This study introduces an innovative approach that integrates Curriculum Learning (CL) with a multi-fidelity surrogate model to enhance computational efficiency in engineering design. A multi-fidelity strategy is introduced to generate training data efficiently, leveraging a high-fidelity finite element model for accurate simulations and a low-fidelity model to provide a larger dataset at reduced computational cost. Unlike conventional surrogate modeling approaches, the proposed method applies CL to iteratively refine the surrogate model, enabling step-by-step learning of complex structural patterns and improving prediction accuracy. Genetic algorithms (GAs) are then applied to optimize structural parameters while minimizing computational expense. The integration of CL and multi-fidelity modeling allows for a reduction in computational burden while preserving accuracy, demonstrating practical applicability in real-world structural design problems. The effectiveness of this methodology is validated by evaluating Pareto front quality using selected performance indicators. Results demonstrate that the proposed approach reduces optimization burden while achieving accurate predictions, highlighting the benefits of integrating surrogate modeling, multi-fidelity analysis, CL, and GAs for efficient composite structure optimization. This work contributes to the advancement of optimization methodologies by providing a scalable framework applicable to complex engineering problems requiring high computational efficiency. Full article

(This article belongs to the Special Issue Numerical Methods and Modeling Applied for Composite Structures)

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17 pages, 7182 KiB

Open AccessArticle

Dynamic Load Identification of Thin-Walled Cabin Based on CNN-LSTM-SA Neural Network

by Jun Wang, Shaowei Song, Chang Liu and Yali Zhao

Materials 2025, 18(6), 1255; https://doi.org/10.3390/ma18061255 - 12 Mar 2025

Viewed by 448

Abstract

Spacecraft are subjected to various external loads during flight, and these loads have a direct impact on the structural safety and functional stability of the spacecraft. Obtaining external load information can provide reliable support for spacecraft health detection and fault warning, so accurate load identification is very important for spacecraft. Compared with the traditional time-domain load identification method, the neural network-based time-domain load identification method can avoid the establishment of the inverse model and realize the response-load time-sequence mapping, which has a broad application prospect. In this paper, a CNN-LSTM-SA neural network-based load identification method is proposed for load acquisition of a thin-walled spacecraft model. Simulation results show that the method has higher identification accuracy and robustness (RMSE and MAE of 8.47 and 10.83, respectively, at a 20% noise level) in the load identification task compared to other network structures. The experimental results show that the coefficients of determination (R²) of the proposed neural network load recognition model for time-domain identification tasks of sinusoidal and random loads are 0.98 and 0.93, respectively, indicating excellent fitting performance. This study provides a reliable new method for load identification in thin-walled spacecraft cabin structures. Full article

(This article belongs to the Special Issue Numerical Methods and Modeling Applied for Composite Structures)

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11 pages, 1950 KiB

Open AccessArticle

Prediction and Experimental Study of Low-Frequency Acoustic and Vibration Responses for an Aircraft Instrument Compartment Based on the Virtual Material Method

by Shaowei Song, Jun Wang, Chang Liu and Rongze Huang

Materials 2025, 18(5), 932; https://doi.org/10.3390/ma18050932 - 20 Feb 2025

Viewed by 415

Abstract

Bolted connections are extensively utilized in aircraft structures, and accurately simulating these connections is a critical factor affecting the precision of vibration and noise response predictions for aircraft. This study focuses on an instrument compartment of a specific aircraft model, employing the virtual material method to simulate the bolted joints within the structure. Parameters for the virtual material layer were obtained through theoretical calculations combined with parameter identification methods, achieving precise modeling of the instrument compartment. By comparing the calculated modes with the experimental modes of the instrument compartment, it was found that the first four modal shapes from both calculation and experiment were completely consistent, with the error in natural frequencies within three percent. Subsequently, acoustic and vibration computations were performed using both the virtual material model and the tied constraint model, with comparisons made against experimental results. The findings indicate that the root mean square (RMS) acceleration response of the virtual material model was 11.23 g, closely matching the experimental value of 10.35 g. Additionally, the total sound pressure level inside the acoustic cavity was 136.98 dB, closely aligning with the experimental value of 135.76 dB. These results demonstrate that the virtual material method offers higher accuracy in structural acoustic and vibration calculations. Full article

(This article belongs to the Special Issue Numerical Methods and Modeling Applied for Composite Structures)

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19 pages, 8834 KiB

Open AccessArticle

Impact Damage Localization in Composite Structures Using Data-Driven Machine Learning Methods

by Can Tang, Yujie Zhou, Guoqian Song and Wenfeng Hao

Materials 2025, 18(2), 449; https://doi.org/10.3390/ma18020449 - 19 Jan 2025

Cited by 1 | Viewed by 933

Abstract

Due to the uncertainty of material properties of plate-like structures, many traditional methods are unable to locate the impact source on their surface in real time. It is important to study the impact source-localization problem for plate structures. In this paper, a data-driven machine learning method is proposed to detect impact sources in plate-like structures and its effectiveness is tested on three plate-like structures with different material properties. In order to collect data on the localization of the impact source, four piezoelectric transducers and an oscilloscope were utilized to construct an experimental platform for impulse response testing. Meanwhile, the position of the impact source on the surface of the test plate is generated by manually releasing the steel ball. The eigenvalue of arrival time in the time domain signal is extracted to build data sets for machine learning. This paper uses the Back Propagation (BP) neural network to learn the difference in the arrival time of each sensor and predict the location of the impact source. The results demonstrate that the machine learning method proposed in this paper can predict the location of the impact source in the plate-like structure without relying on the material properties, with high test accuracy and robustness. The research work in this paper can provide experimental methods and testing techniques for locating impact damage in composite material structures. Full article

(This article belongs to the Special Issue Numerical Methods and Modeling Applied for Composite Structures)

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11 pages, 2835 KiB

Open AccessArticle

Some Unfamiliar Structural Stability Aspects of Unsymmetric Laminated Composite Plates

by Mehdi Bohlooly Fotovat

Materials 2024, 17(15), 3856; https://doi.org/10.3390/ma17153856 - 4 Aug 2024

Cited by 1 | Viewed by 1033

Abstract

It is widely recognized that certain structures, when subjected to static compression, may exhibit a bifurcation point, leading to the potential occurrence of a secondary equilibrium path. Also, there is a tendency of deflection increment without a bifurcation point to occur for imperfect structures. In this paper, some relatively unknown phenomena are investigated. First, it is demonstrated that in some conditions, the linear buckling mode shape may differ from the result of geometrically nonlinear analysis. Second, a mode jumping phenomenon is described as a transition from a secondary equilibrium path to an obscure one as a tertiary equilibrium path or a second bifurcation point. In this regard, some non-square plates with unsymmetric layer arrangements (in the presence of extension–bending coupling) are subjected to a uniaxial in-plane compression. By considering the geometrically linear and nonlinear problems, the bucking modes and post-buckling behaviors, e.g., the out-of-plane displacement of the plate versus the load, are obtained by ANSYS 2023 R1 software. Through a parametric analysis, the possibility of these phenomena is investigated in detail. Full article

(This article belongs to the Special Issue Numerical Methods and Modeling Applied for Composite Structures)

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15 pages, 10591 KiB

Open AccessArticle

Ultrasonic Welding of Acrylonitrile–Butadiene–Styrene Thermoplastics without Energy Directors

by Qian Zhi, Yongbing Li, Xinrong Tan, Yuhang Hu and Yunwu Ma

Materials 2024, 17(15), 3638; https://doi.org/10.3390/ma17153638 - 23 Jul 2024

Viewed by 1296

Abstract

Ultrasonic welding (USW) of thermoplastics plays a significant role in the automobile industry. In this study, the effect of the welding time on the joint strength of ultrasonically welded acrylonitrile–butadiene–styrene (ABS) and the weld formation mechanism were investigated. The results showed that the peak load firstly increased to a maximum value of 3.4 kN and then dropped with further extension of the welding time, whereas the weld area increased continuously until reaching a plateau. The optimal welding variables for the USW of ABS were a welding time of 1.3 s with a welding pressure of 0.13 MPa. Interfacial failure and workpiece breakage were the main failure modes of the joints. The application of real-time horn displacement into a finite element model could improve the simulation accuracy of weld formation. The simulated results were close to the experimental results, and the welding process of the USW of ABS made with a 1.7 s welding time can be divided into five phases based on the amplitude and horn displacement change: weld initiation (Phase I), horn retraction (Phase II), melt-and-flow equilibrium (Phase III), horn indentation and squeeze out (Phase IV) and weld solidification (Phase V). Obvious pores emerged during Phase IV, owing to the thermal decomposition of the ABS. This study yielded a fundamental understanding of the USW of ABS and provides a theoretical basis and technological support for further application and promotion of other ultrasonically welded thermoplastic composites. Full article

(This article belongs to the Special Issue Numerical Methods and Modeling Applied for Composite Structures)

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15 pages, 8569 KiB

Open AccessArticle

Numerical Simulation of Compressive Mechanical Properties of 3D Printed Lattice-Reinforced Cement-Based Composites Based on ABAQUS

by Weiguo Wu, Jing Qiao, Yuanyuan Wei, Wenfeng Hao and Can Tang

Materials 2024, 17(10), 2370; https://doi.org/10.3390/ma17102370 - 15 May 2024

Cited by 2 | Viewed by 2052

Abstract

Research has established that the incorporation of 3D-printed lattice structures in cement substrates enhances the mechanical properties of cementitious materials. However, given that 3D-printing materials, notably polymers, exhibit varying degrees of mechanical performance under high-temperature conditions, their efficacy is compromised. Notably, at temperatures reaching 150 °C, these materials soften and lose their load-bearing capacity, necessitating further investigation into their compressive mechanical behavior in such environments. This study evaluates the compressibility of cement materials reinforced with lattice structures made from polyamide 6 (PA6) across different structural configurations and ambient temperatures, employing ABAQUS for simulation. Six distinct 3D-printed lattice designs with equivalent volume but varying configurations were tested under ambient temperatures of 20 °C, 50 °C, and 100 °C to assess their impact on compressive properties. The findings indicate that heightened ambient temperatures significantly diminish the reinforcing effect of 3D-printed materials on the properties of cement-based composites. Full article

(This article belongs to the Special Issue Numerical Methods and Modeling Applied for Composite Structures)

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18 pages, 8275 KiB

Open AccessArticle

Buckling Analysis of Thin-Walled Composite Structures with Rectangular Cross-Sections under Compressive Load

by Patryk Rozylo, Michal Rogala and Jakub Pasnik

Materials 2023, 16(21), 6835; https://doi.org/10.3390/ma16216835 - 24 Oct 2023

Cited by 8 | Viewed by 1665

Abstract

The purpose of this research was the analysis of the stability of compressed thin-walled composite columns with closed rectangular cross-sections, subjected to axial load. The test specimens (made of carbon–epoxy composite) were characterized by different lay-ups of the composite material. Experimental tests were carried out using a universal testing machine and other interdisciplinary testing techniques, such as an optical strain measurement system. Simultaneously with the experimental studies, numerical simulations were carried out using the finite element method. In the case of FEA simulations, original numerical models were derived. In the case of both experimental research and FEM simulations, an in-depth investigation of buckling states was carried out. The measurable effect of the research was to determine both the influence of the cross-sectional shape and the lay-up of the composite layers on the stability of the structure. The novelty of the present paper is the use of interdisciplinary research techniques in order to determine the critical state of compressed thin-walled composite structures with closed sections. An additional novelty is the object of study itself—that is, thin-walled composite columns with closed sections. Full article

(This article belongs to the Special Issue Numerical Methods and Modeling Applied for Composite Structures)

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17 pages, 5471 KiB

Open AccessArticle

Buckling Analysis of Laminated Plates with Asymmetric Layup by Approximation Method

by Katarzyna Falkowicz, Pawel Wysmulski and Hubert Debski

Materials 2023, 16(14), 4948; https://doi.org/10.3390/ma16144948 - 11 Jul 2023

Cited by 11 | Viewed by 2071

Abstract

This study investigated thin-walled plate elements with a central cut-out under axial compression. The plates were manufactured from epoxy/carbon laminate (CFRP) with an asymmetric layup. The study involved analyzing the buckling and post-buckling behavior of the plates using experimental and numerical methods. The experiments provided the post-buckling equilibrium paths (P-u), which were then used to determine the critical load using the straight-line intersection method. Along with the experiments, a numerical analysis was conducted using the Finite Element Method (FEM) and using the ABAQUS^® software. A linear analysis of an eigenvalue problem was conducted, the results of which led to the determination of the critical loads for the developed numerical model. The second part of the calculations involved conducting a non-linear analysis of a plate with an initial geometric imperfection corresponding to structural buckling. The numerical results were validated by the experimental findings, which showed that the numerical model of the structure was correct. Full article

(This article belongs to the Special Issue Numerical Methods and Modeling Applied for Composite Structures)

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19 pages, 10584 KiB

Open AccessArticle

Failure Mechanism of Tensile CFRP Composite Plates with Variable Hole Diameter

by Pawel Wysmulski

Materials 2023, 16(13), 4714; https://doi.org/10.3390/ma16134714 - 29 Jun 2023

Cited by 15 | Viewed by 1794

Abstract

Real thin-walled composite structures such as aircraft or automotive structures are exposed to the development of various types of damage during operation. The effect of circular hole size on the strength of a thin-walled plate made of carbon fibre-reinforced polymer (CFRP) was investigated in this study. The test object was subjected to tensile testing to investigate the strength and cracking mechanism of the composite structure with variable diameter of the central hole. The study was performed using two independent test methods: experimental and numerical. With increasing diameter of the central hole, significant weakening of the composite plate was observed. The study showed qualitative and quantitative agreement between the experimental and numerical results. The results confirmed the agreement of the proposed FEM model with the experimental test. The novelty of this study is the use of the popular XFEM technique to describe the influence of the hole size on the cracking and failure of the composite structure. In addition, the study proposes a new method for determining the experimental and numerical damage and failure loads of a composite plate under tension. Full article

(This article belongs to the Special Issue Numerical Methods and Modeling Applied for Composite Structures)

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