Improving Damage Modelling in Aerospace Design: Stress transfer across cracks.
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Design in the aerospace sector relies heavily on understanding material behaviour under diverse stress conditions to ensure safety and performance. Simulation has emerged as a powerful tool, significantly reducing the need for extensive physical testing. This approach lowers costs, saves time, and enables more efficient design optimisation. However, creating realistic and reliable models requires substantial expertise and knowledge. One key challenge is accurately modelling crack behaviour, particularly stress transfer across fully open cracks. Once the material has undergone complete softening, the crack is fully open, and stress transfer across it should no longer occur. However, it has been observed that stress begins to rise again beyond this stage, indicating an unexpected transfer of stress across the open crack. This behaviour results in unrealistic damage modes, distorting the true material response and reducing the model’s accuracy in predicting crack propagation and overall structural performance. To address these challenges, a method involving objective derivatives and rotated frames based on fibre rotation, rather than the Green-Naghdi stress objectives in Abaqus, is proposed. This approach eliminates the unrealistic stress transfer across open cracks, significantly improving the accuracy of damage progression and crack propagation predictions. By aligning simulations more closely with experimental results, it enhances the reliability of predictive models and contributes to more robust aerospace designs.