Comparative Evaluation of Failure analysis methods for

Composite Materials

Aim of Lamina Failure Analysis : 1) Strength determination

2)Mode of failure (in composite)

Flaws in Lamina Failure Analysis :

The various failure theories( maximum stress , maximum strain, Hill-Tsai, Tsai-Wu, Hashin Rotem ,
Hashin ) are based on Curve fitting methods (Phenemenological) and studies carried out are on the
assumption of linear elasticity. Roughly the failure load depends on the equations developed.
Failure is defined only for 2D Orthotropic materials (transversely isotropic) with following notations
for Strength.

X & X’ = Tenslle and Compressive strengths in Fibre Direction

Y & Y’ = Tenslle and Compressive strengths in Transverse Direction

S = Shear Strength

Modes of Failure in Lamina are Defined as :

If σ11 or Є11 dominates => Fibre Failure

If σ22 or Є22 dominates => Transverse Matrix cracking

If τ12 dominates => Shea r Matrix cracking

Failure Envelopes were constructed based on Moduli and Strength Values of AS4/3501-6/GRAPHITE
EPOXY SYSTEM that were tested previously.

The failure cases investigated for different stress combinations is as follows :

(i) Combined stress in σ11 - σ22 Plane(with τ12 = 0)

Max Stress Max Strain Tsai-Wu Hill-Tsai Hashim Rotem Hashim
Rectangle Skewed Ellipse Ellipse Rectangle Rectangle
Envelope Rectangle extending Envelope Envelope
in
longitudinal
axis for σ22
(ii) Combined stress in σ11- τ12 Plane (with σ22 = 0)
Max Stress Max Strain Tsai-Wu Hill-Tsai Hashim Rotem Hashim
Rectangle Rectangle Intersects Intersects Rectangle Rectangle
Envelope Envelope only at only at Envelope Envelope
3points of 3points of
other other
failure failure
criteria criteria

(iii) Combined stress in σ22- τ12 Plane (with σ11 = 0)

Max Stress Max Strain Tsai-Wu Hill-Tsai Hashim Rotem Hashim
Rectangle Rectangle Linear term Ellipse Ellipse taking Ellipse
With more With more Of Tsai-Wu taking compressive taking
area area (σ22)pushed compressive (σ22) loading compressive
towards towards failure (σ22) loading more than (σ22) loading
compression compression envelope more than tensile loading more than
Side(σ22) Side(σ22) beyond tensile tensile
shear loading loading
strength

(iv) Off Axis Loading in σ11= σxx & σ22=0 (for θ = 0)

Max Stress Max Strain Tsai-Wu Hill-Tsai Hashim Rotem Hashim
Defines Curve From 0-10 From 0-10 Same as max Initially
separate almost degrees, it degrees, it stress theory matches
modes of same as predicts predicts from 0- with Hill-
failures that of max less stress less stress 2.7degrees , Tsai upto
(critical stress (σ11 ) than (σ11 ) than then follows 10degrees,
angles Stress & Stress & Hill-Tsai upto 90 Shift
0,2.9,27.1 strain strain occurs and
indicates theories theories merges
change in once again
failure at
mode 90degrees.

(v) Pure Shear in τ12 = τxy & σ11 = σ22 = 0 (for θ = 0) ;

Max Stress Max Strain Tsai-Wu Hill-Tsai Hashim Rotem Hashim
Shear Same as Same as Same as Same as Same as
matrix column1 column1 column1 column1 column1
cracking
from 0-30.8
degress,
while
transverse
matrix
cracking
fom 30.8-
45degrees
Summary of theories Studied :
 Maximum Stress & Strain Theories : Presumed failure occurs without interaction b/n
stresses & strains respectively. Proposed equations involving only 1Stress & 1Strain
term respectively.
 Hill-Tsai , Tsai –Wu : Developed Quadratic Equation and assumes , failure occurs when
equation is satisfied .
 Hashin-Rotem , Hashin : Proposed matrix failure independent of fibre but unlike
maximum stress and strain criteria , they consider 1 or more stress components ,
admitting the reason for failure.

σ11/X = 1 for fibre failure

(σ22/X)2 + (τ12/S)2 = 1 for Matrix failure

( It has been modified to (σ22/X)2 + (τ12/S-µσ22)2 = 1 ; considering the fibre/matrix

interface experiencing more normal stress than shear stress i.e.,
σ22=σ0(𝑎𝑝𝑝𝑙𝑖𝑒𝑑) >> τ12

Laminate Failure Analysis:

Assumptions:
 Strength is based on assumption of 2D stresses in laminate.
 Progressive failure takes in constituent laminae upon the application of load.
 Laminate is free from edge stress and failure donot proceed from free edges.

Hence as lamina failure is progressive in nature, progressive loss of lamina stiffness has to be
considered for laminate analysis.

Laminate Failure Analysis Methods :

1)Ply by Ply Discount Method :
 Laminate: Homogeneous material
 Laminate Plate Theory helps in evaluation of state of stress and strain in each ply.
Subsequently , lamina failure theory is used to identify ply that fails and accordingly, mode
of failure is known. Stiffness reduction model(parallel spring model) employed decreases
the stiffness of laminate ( since individually ply failure is resulted). The cycle is repeated until
ultimate laminate failure occurs.
2)Sudden Failure Method:
 Lamina Ultimate strength has no effect on progressive stiffness reduction of matrix.
 Considers lamina failure is equivalent to failure load taken by fibre carrying ply.(i.e., matrix is
excluded). Therefore Laminate strength predicted by sudden failure method is greater than
Ply by Ply method.

3)Direct Laminate Method:

 Considers Laminate as whole , in evaluating strength equations that governs the failure.
Change in layout of the laminate would bring different strengths. Hence this is not
preferred.

Laminate Failure Results:

Upon testing AS4/3501-6 GRAPHITE- EPOXY Composite subjecting to Half axis loading under various
combinations of them, it was observed

 If fibre is being dominated in laminate, Maximum stress/strain/Hashin-Roten theories can

be used for strength prediction.
 If matrix is dominated in laminate, all criteria for analysis can be used and report failure
when excessive strains occurs.
 To assess matrix failure, insitu transverse strength and shear strength is considered.