ALBERT

Description: A surrogate model methodology is described for predicting in real time the residual strength of flight structures with discrete-source damage. Starting with design of experiment, an artificial neural network is developed that takes as input discrete-source damage parameters and outputs a prediction of the structural residual strength. Target residual strength values used to train the artificial neural network are derived from 3D finite element-based fracture simulations. A residual strength test of a metallic, integrally-stiffened panel is simulated to show that crack growth and residual strength are determined more accurately in discrete-source damage cases by using an elastic-plastic fracture framework rather than a linear-elastic fracture mechanics-based method. Improving accuracy of the residual strength training data would, in turn, improve accuracy of the surrogate model. When combined, the surrogate model methodology and high-fidelity fracture simulation framework provide useful tools for adaptive flight technology.

Description: This paper summarizes recent results on simulating full-scale pressure tests of wide body, lap-jointed fuselage panels with multiple site damage (MSD). The crack tip opening angle (CTOA) fracture criterion and the FRANC3D/STAGS software program were used to analyze stable crack growth under conditions of general yielding. The link-up of multiple cracks and residual strength of damaged structures were predicted. Elastic-plastic finite element analysis based on the von Mises yield criterion and incremental flow theory with small strain assumption was used. A global-local modeling procedure was employed in the numerical analyses. Stress distributions from the numerical simulations are compared with strain gage measurements. Analysis results show that accurate representation of the load transfer through the rivets is crucial for the model to predict the stress distribution accurately. Predicted crack growth and residual strength are compared with test data. Observed and predicted results both indicate that the occurrence of small MSD cracks substantially reduces the residual strength. Modeling fatigue closure is essential to capture the fracture behavior during the early stable crack growth. Breakage of a tear strap can have a major influence on residual strength prediction.

Description: In the course of several years of research efforts to predict crack turning and flapping in aircraft fuselage structures and other problems related to crack turning, the 2nd order maximum tangential stress theory has been identified as the theory most capable of predicting the observed test results. This theory requires knowledge of a material specific characteristic length, and also a computation of the stress intensity factors and the T-stress, or second order term in the asymptotic stress field in the vicinity of the crack tip. A characteristic length, r(sub c), is proposed for ductile materials pertaining to the onset of plastic instability, as opposed to the void spacing theories espoused by previous investigators. For the plane stress case, an approximate estimate of r(sub c), is obtained from the asymptotic field for strain hardening materials given by Hutchinson, Rice and Rosengren (HRR). A previous study using of high order finite element methods to calculate T-stresses by contour integrals resulted in extremely high accuracy values obtained for selected test specimen geometries, and a theoretical error estimation parameter was defined. In the present study, it is shown that a large portion of the error in finite element computations of both K and T are systematic, and can be corrected after the initial solution if the finite element implementation utilizes a similar crack tip discretization scheme for all problems. This scheme is applied for two-dimensional problems to a both a p-version finite element code, showing that sufficiently accurate values of both K(sub I) and T can be obtained with fairly low order elements if correction is used. T-stress correction coefficients are also developed for the singular crack tip rosette utilized in the adaptive mesh finite element code FRANC2D, and shown to reduce the error in the computed T-stress significantly. Stress intensity factor correction was not attempted for FRANC2D because it employs a highly accurate quarter-point scheme to obtain stress intensity factors.

Description: Asimple, nonstandardized material test specimen,which fails along one of two different likely crack paths, is considered herein.The result of deviations in geometry on the order of tenths of amillimeter, this ambiguity in crack pathmotivates the consideration of asmanufactured component geometry in the design, assessment, and certification of structural systems.Herein, finite elementmodels of as-manufactured specimens are generated and subsequently analyzed to resolve the crack-path ambiguity. The consequence and benefit of such a "personalized" methodology is the prediction of a crack path for each specimen based on its as-manufactured geometry, rather than a distribution of possible specimen geometries or nominal geometry.The consideration of as-manufactured characteristics is central to the Digital Twin concept. Therefore, this work is also intended to motivate its development.