Composite Durability Analysis via Frequency Domain Modeling

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Solution Overview

Problem

Predicting the behavioral characteristics of composite materials over time in response to loads is challenging due to their complex nature, particularly in structures like commercial aircraft, where traditional methods fail to accurately simulate diffused damage and load transmission.

Innovation Solution

A method and system for analyzing durability by performing load-controlled testing to relate critical strain invariants to cyclic rates and frequencies, using laminate properties and geometrical definitions to create a parametric model, and determining frequency responses to identify damage initiation and progression in composite materials.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If traditional testing methods are used to predict behavioral characteristics of composite materials, then extensive coupon testing is required, but this increases time consumption and cost

Engineering Contradiction:
Improveprediction accuracy of behavioral characteristicsVSAvoiddesign cycle time
Core Design Contradiction:
Measurement precisionVSLoss of time

Solution Approach 1:

The patent creates a computational model that copies and simulates the physical behavior of composite materials under various loading conditions. Instead of conducting extensive physical coupon tests, the model replicates material responses to loads, allowing prediction of behavioral characteristics including damage initiation and progression. This virtual copying approach maintains prediction accuracy while eliminating time-consuming physical testing iterations.

Inventive Principle:
Principle #26Copying

Solution Approach 2:

The patent establishes material behavior models and damage progression rules in advance, before actual design iterations are needed. By pre-defining how composite materials respond to different loading conditions and damage states, the system enables rapid prediction during design cycles without requiring real-time or post-hoc extensive testing, thus reducing overall design time while maintaining accuracy.

Inventive Principle:
Principle #10Preliminary action

2Measurement precision

If traditional testing methods are used to predict behavioral characteristics of composite materials, then extensive coupon testing is required, but this increases cost

Engineering Contradiction:
Improveprediction accuracy of behavioral characteristicsVSAvoidtesting cost
Core Design Contradiction:
Measurement precisionVSEase of manufacture

Solution Approach 1:

The computational model serves as a virtual substitute for physical coupon testing, copying material behavior through mathematical representations rather than physical specimens. This approach maintains the ability to predict behavioral characteristics accurately while eliminating the recurring costs of material procurement, testing setup, and physical experimentation associated with traditional methods.

Inventive Principle:
Principle #26Copying

Solution Approach 2:

The patent replaces the mechanical testing system with a computational analysis system. Instead of physically loading coupon specimens and measuring responses, the system uses computational models to simulate mechanical behavior, substitute physical measurement with calculation, and replace laboratory equipment with software algorithms, thereby eliminating testing costs while preserving prediction capability.

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If traditional methods are used to simulate damage in composite structures, then damage cannot be accurately simulated, but switching to new methods requires complex frequency-domain analysis

Engineering Contradiction:
Improvedamage simulation accuracyVSAvoidanalysis method complexity
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The patent introduces frequency-domain analysis as an intermediary approach between simple time-domain methods and complex physical testing. The frequency-domain formulation serves as a mathematical mediator that captures damage accumulation effects through spectral analysis of loading histories, providing accurate damage simulation without requiring the full complexity of time-dependent material models or extensive physical testing programs.

Inventive Principle:
Principle #24Intermediary (Mediator)

Data Source

PatentUS10309883B2Analyzing structural durability in the frequency domain
Publication Date: 2019.06.04 THE BOEING CO
  • US10309883B2 patent drawing
  • US10309883B2 patent drawing
  • US10309883B2 patent drawing

AI summary

A method of analyzing the durability of a structure. Load-controlled testing is performed on samples of a composite material of the structure to relate critical strain invariants of the material to cyclic rates of strain invariant accumulation and frequencies associated with the cyclic rates. The material is characterized based on effective properties of the material, including the cyclic rates of strain invariant accumulation. Laminate properties and a geometrical definition of the structure are used to obtain a parametric model. Material characterizations are used to determine model element frequency responses to applied load conditions. Each element's frequency responses and critical strain invariants are used to determine whether damage is indicated at the element. Progression of damage is tracked and accounted for in the model.