Composite Ply Damage Assessment Using FEM-NDE Correlation
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Solution Overview
Problem
Current methods for predicting damage in multi-ply composite structures using nonlinear explicit finite element analysis are complex and lack a standard process for cross-validation, requiring engineers to visually compare results from multiple finite element models with non-destructive evaluation methods, which is time-consuming and not very accurate.
Innovation Solution
A computer system generates weighting factors to correlate predicted damage values with actual damage values, creating a transfer function that converts predicted damage into estimated damage, and generates a parametric model defining the damage boundary, which can be displayed to users, improving prediction accuracy and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional finite element analysis methods are used to predict damage to composite materials, then damage prediction can be performed in a non-destructive manner, but the analysis process becomes complex and requires multiple different FEM models yielding different results
Solution Approach 1:
The patent combines multiple FEM models into a single unified model that integrates the strengths of different modeling approaches. This unified model correlates predicted damage values with actual NDE measurements, eliminating the need to manually compare results from multiple separate models while maintaining comprehensive damage prediction capabilities across different ply configurations.
Solution Approach 2:
The patent introduces correlation factors as adjustable parameters that optimize the relationship between FEM predictions and actual damage. By varying these correlation factors, the model adapts to different composite configurations and impact scenarios, improving prediction accuracy without requiring complex manual calibration of multiple separate models.
2Measurement precision
If engineers visually compare results of different FEM models with NDE scan images, then cross-validation can be performed, but the process is time-consuming and not very accurate
Solution Approach 1:
The patent replaces the manual visual comparison process with an automated computational system. The unified FEM model automatically correlates predicted damage values with actual NDE measurements through mathematical correlation factors, eliminating the need for engineers to manually overlay and compare images while significantly improving measurement precision through quantitative analysis.
Solution Approach 2:
The patent introduces correlation factors as intermediary parameters that bridge the gap between FEM predictions and actual damage measurements. These correlation factors serve as a mathematical mediator that quantifies the relationship between predicted and actual damage, enabling automated cross-validation without manual intervention.
3Adaptability or versatility
If multiple FEM models are used to predict damage, then comprehensive coverage of different damage scenarios is achieved, but there is no standard process for adopting results and utilizing them for cross-validation
Solution Approach 1:
The patent creates a universal unified FEM model that can handle multiple damage scenarios, ply configurations, and impact conditions through a single standardized framework. This universal model incorporates correlation factors that adapt to different scenarios, providing comprehensive coverage while maintaining ease of operation through a consistent analysis process.
Solution Approach 2:
The patent segments the damage prediction process into distinct correlation factors for different ply configurations and damage modes. This segmentation allows the unified model to systematically address various damage scenarios while maintaining a standardized process for result adoption and cross-validation.
Data Source
AI summary
A computer is configured to enable a rapid, consistent, ply-by-ply, quantitative analytical assessment of various Finite Element Method (FEM) material models based on metrics defined for impact damage. Additionally, the computer is configured to provide a method for determining the accuracy of such FEM material model(s) by comparing the output of those models to non-destructive evaluation (NDE) test data.