FINITE ELEMENT ANALYSIS OF SMART FUNCTIONALLY GRADED COMPOSITE SHELL STRUCTURE A THESIS SUBMITTED IN PARTIAL REQUIREMENTS FOR THE DEGREE OF Bachelor of Technology In Mechanical Engineering By ABHIJEET NAYAK Roll No. – 10503004 Department of Mechanical Engineering National Institute of Technology, Rourkela May, 2009 National Institute of Technology Rourkela CERTIFICATE This is to certify that this report entitled, “FINITE ELEMENT ANALYSIS OF SMART FUNCTIONALLY GRADED COMPOSITE SHELL STRUCTURE” submitted by Abhijeet Nayak in partial fulfillments for the requirements for the award of Bachelor of Technology Degree in Mechanical Engineering at National Institute of Technology, Rourkela (Deemed University) is an authentic work carried out by her under my supervision and guidance. To the best of my knowledge, the matter embodied in this report has not been submitted to any other University / Institute for the award of any Degree or Diploma Date: Rourkela NIT (Prof. T. Roy) Dept. of Mechanical Engineering, National Institute of Technology Rourkela - 769008, Orissa ACKNOWLEDGEMENT I deem it a privilege to have been a student of Mechanical Engineering stream in National Institute of Technology, Rourkela I express my deep sense of gratitude and obligation to my project guide Prof. T. Roy for his invaluable guidance and support. I am very grateful to him for allowing me to do this project and for his constant help and support throughout the making of this project. He always bestowed parental care upon us and evinced keen interest in solving our problems. An erudite teacher, a magnificent person and a strict disciplinarian, we consider ourselves fortunate to have worked under his supervision. Abhijeet Nayak Roll No. – 10503004 8th Semester, B.TECH Department of Mechanical Engineering National Institute of Technology, Rourkela ABSTRACT Composite materials and structures are finding wide acceptance because of their stiffnessto-weight ratio that is particularly favorable. The main drawback of laminated composites, which is the weakness of interfaces between adjacent layers known as delimitation phenomena, that may lead to structural failure has been partially overcome by developing a new class of materials named Functionally Graded Materials. Recently proposed (FGMs) have their various material properties vary through the thickness in a continuous manner and thus free from interface weakness, typical of laminated composites. This project deals with the modeling of functionally graded doubly curved shells, with the material properties graded in the thickness direction. Finite element modeling based on first order shear deformation theory is used The effect of grading on the deformation of the FGM shells in a given temperature boundary conditions has been studied. Focus has also been put on Elemental model for static analysis of smart functionally graded shells attached with distributed piezoelectric sensor and actuator. Eight noded element with five degrees of freedom per node, three translational and two rotations have been used. The electric field is applied in the thickness direction and assumed to be constant through the thickness. The electrical potential is assumed to be constant over the element. Also, effective coefficients of recently proposed Piezoelectric Fiber Reinforced Composite (PFRC) have been derived through micro-mechanical analysis. The strength of materials approach has been employed to predict the coefficients the static analysis of FGM shells has been done using this PFRC actuator. i CONTENTS Chapter Title Page no. Abstract i Contents ii- vi Nomenclature vii-x Chapter 1 Introduction 1-7 1.1 Composite materials 1 1.2 Drawbacks of laminated composites 1 1.3 Functionally graded materials 1 1.4 FGMs in nature 2 1.5 Effective properties of heterogeneous/multiphase materials 1.6 Smart Structures 3 3 1.7 Critical Elements in a smart structure 4 1.7.1 Actuators 4 1.7.2 Sensors 5 1.7.3 Control System 5 ii 1.7.4 Piezoelectric materials 5 1.8 Piezoelectric Fiber Reinforced Composites 5 1.9 Motivation of the present work 5 1.10 Applications of FGM/ smart FGM structures Chapter 2 Background and literature review 2.1 General 6 8-12 9 2.2 Thermal stress analysis and applications 9 2.3 Fracture and creep analysis 10 2.4 Exact and analytical solutions 10 2.5 Vibration and control 10 2.6 Smart structures and Functionally Graded Materials 11 2.7 Piezoelectric Fiber Reinforced Composite (PFRC) 11 2.8 Objectives of present work 12 2.9 Layout of the thesis Chapter 3 12 Determination of effective properties of PFRC layer 3.1 Assumptions involved in the analysis 13-19 13 iii 3.2 Strength of material approach 14 3.3Effective coefficients of PFRC layer Chapter 4 17 Formulation 20-39 4.1Introduction 20 4.2 Geometry and kinematics of doubly curved shell element 21 4.2.1Assumptions in the model development 21 4.2.2 Shell geometry considerations 21 4.2.3 Discretization of shell global space to isoparametric space 4.2.4 Displacement field and strains for shell element 23 24 4.2.5 Isoparametric Finite Element approximation of displacement field and electric field for plate element 4.2.6 Jacobian matrix (Transformation matrix) 24 26 4.3 Governing differential equations 27 4.4. Static finite element equations 28 4.4.1 Mechanical strain energy 28 4.4.2 Electrical potential energy 30 iv 4.4.3 Work done by the external forces and electrical charge 30 4.5 Dynamic finite element equations 32 4.6 Thermal load 37 4.7 Piezoelectric patches 37 4.8 Thermal analysis to determine temperature distribution in the thickness direction 38 4.9 Element mass matrix Chapter 5 39 Results and discussion 40-50 5 Validation of Finite Element Code of doubly curved shell element 5.1 Static mechanical shell element 40 41 5.2 Static thermo-mechanical analysis of the shell element 42 5.3 Validation of electromechanical coupling of the piezoelectric materials using doubly curved shell element 43 v 5.3.1 PFRC actuator integrated on the surface of a doubly curved shell 43 5.4 Variations in response due to various types of loadings 45 5.4.1 Variations in response due to pure thermal loading 45 5.4.2 Variations in response due to pure mechanical loading 46 5.4.3 Variations in response due to thermo- mechanical loading 47 5.4.4 Variations in response due to electro-thermo- mechanical loading 5.5 Scope for future work 48 51 vi NOMENCLATURE σx ,σy ,σxy ,σxz ,σyz Components of Stress vector in the global or, σ1 ,σ2 ,σ12 ,σ13 ,σ23 Coordinate system εx , εy , εxy , εxz , εyz or, ε1 , ε2 , ε12 , ε13 , ε 23 Components of Strain vector in the global Coordinate system σ’x ,σ’y ,σ’xy ,σ’xz ,σ’yz Components of Stress vector in the local or, σ’1 ,σ’2 ,σ’12 ,σ’13 ,σ’23 Coordinate system ε’x , ε’y , ε’xy , ε’xz , ε’yz or, ε’1 , ε’2 , ε’12 , ε’13 , ε’23 αik Components of Strain vector in the local Coordinate system Vectors defining the nodal coordinate system at the node in degenerate shell element ζ A linear natural coordinate in the thickness direction x,y,z Global space α1 , α 2 Parametric space (in shell) x’,y’,z’ Local co-ordinates system of layers vii ξ and η Natural/isoparametric space of shell element u, v, w Displacement components of any point in the shell space Φx , Φy {de},{d} Rotation of yz and xz planes due to bending Mechanical degrees of freedom vector at the element and global level, respectively cElastic matrix v,µ Poisson’s ratio h Thickness of the FG shell/plate E1,E2 Modulus of elasticity at the top and bottom of the FG layer, respectively λ Parameter of gradation on FG layer {D} Electric displacement vector [Є] Dielectric matrix at constant mechanical strain R 1, R 2 , R 3 Radii of curvature of doubly curved shells A1 , A2 Lame’s parameters for doubly curved shell eij Piezoelectric coefficients viii {Ge} , {G} Electric force vector resulting from the applied charge density on the the actuator at the element and the global level, respectively F e ,FMechanical force vector resulting from the vector resulting from the level, respectively T Kinetic energy Total potential energy of the entire structure U Strain energy of the entire structure {E}Electric field vector TΘ,T1 ,T2 Stress free temperature, temperature at bottom, temperature at top, respectively NMT Thermal load vector N T, M T Thermal force, thermal moment ix Abbreviations used FOST First Order Shear Deformation Theory PVDF Polyvinylidene fluoride PZT Lead Zirconate Titanate PFRC Piezoelectric Fiber Reinforced Composite ITER International Thermonuclear Energy Reactor x CHAPTER-1 INTRODUCTION 1.1 Composite materials Composite materials are engineered materials made from two or more constituent materials with significantly different physical or chemical properties which remain separate and distinct on a macroscopic level within the finished structure.They have varied applications including army and aerospace vehicles, nuclear reactor vessels, turbines, buildings , smart highways as well as in sports equipment and medical prosthetics. Our area of interest are Laminated composite structures consisting of several layers of different reinforced laminate bonded together to obtain desired fibre- structural properties (e.g. stiffness, strength, wear resistance, damping,etc). Varying the lamina thickness, lamina material properties, and stacking sequence the desired structural properties can be achieved. Composite materials exhibit high strength-to weight and stiffness-to-weight ratios, which make them ideally suited for use in weight sensitive structures. This weight reduction of structures leads to improvement of their structural performance especially in aerospace applications. 1.2 Drawbacks of laminated composites Though laminated composites have an edge over conventional materials, their major drawback is the weakness of interfaces between adjacent layers, known as delamination phenomena that may lead to failure of the structure. Additional problems include the presence of residual stresses due to the difference in coefficient of thermal expansion of the fiber and matrix. The effects of interlaminar stresses become more profound when laminated composites are subjected to extreme temperatures which leads to failure of composite structure due to delamination. In order to overcome these problems the sudden change of material properties has to be taken care of. 1.3 Functionally graded materials In “Functionally Grad e d Materials” (FGMs) the material properties are graded in a 1 predetermined manner. Thus, Functionally Graded Materials (FGMs) are an advancement of composite materials where the composition or the microstructure is locally varied so that a certain variation of the local material properties is achieved. FGM is also defined as, composites in which the volume fraction of two or more materials are achieved continuously as a function of position along certain directions of the structure to achieve properties as a required function. e.g. mixture of ceramic and metal. By grading the material properties in a continuous manner, the effect of interlaminar stresses developed at the interfaces of the laminated composite due to abrupt change of material properties between neighbouring laminas is mitigated. Thin walled members, i.e., plates and shells, used in reactor vessels, turbines and other machine parts are susceptible to failure from buckling, large amplitude deflections, or excessive stresses induced by thermal or combined thermo mechanical loading. Here FGM’s can fill the void. Thus, FGMs are primarily used in structures subjected to extreme temperature environment or where high temperature gradients are encountered. They are typically manufactured from isotropic components such as metals and ceramics since they are mainly used as thermal barrier structures in environments with severe thermal gradients (e.g. reactor vessels, semiconductor industry).In such conditions ceramic provides heat and corrosion resistance, while the metal provides the strength and toughness. Presently intensive work is being done on for the manufacturing of a thermal plasma shield made for the ITER (International Thermonuclear Energy Reactor). As FGMs are the only possible materials to withstand the extreme temperatures developed within a reactor, without failure. 1.4 FGMs in nature Nature has designed all-biological load carriers such as stems of plants, trunks of trees, bones and other hard tissues in such a way that they incorporate FGM structures by a natural process of optimization and adaptation to their loading & boundary conditions. Their constituents and geometry change continuously adjust to their physical environment. For e.g. specific modulus and specific strength of pure bamboo fiber and shaft of a feather is comparable to that of engineering alloy and ceramics. 2 1.5 Smart Structures Essentially, a smart structural system is a multifunctional unit. It consists of a load (electrical, thermal, magnetic, or mechanical) bearing part, which is usually passive, and an active material part that performs the operations of sensing and actuating. Newnham’s definition, says “The structures with surface mounted or embedded sensors and actuators with the capability to sense and take corrective action” smart structures. E.g, Vibration amplitudes in a flexible plate structure may be suppressed using the sensing and actuation capabilities of piezoelectric or piezoceramic films by bonding them to the surfaces of the plate. As the plate deforms due to external applied loads, the bonded piezoelectric film (sensor) also deforms, and due to its constitutive behavior, it develops a surface charge proportional to the applied force. The charge may be processed by a control system, which supplies an appropriate voltage to the piezoelectric film (actuator) that induces a counteractive deformation to the plate structure and suppresses the amplitudes of the vibrations. The commonly used smart materials are piezoelectric materials, magnetostrictive materials, electrostrictive materials, shape memory alloys, fiber optics, and electro rheological fluids. Each smart material has a unique advantage of its own. 1.6 Effective properties of heterogeneous/multiphase materials As FGMs are heterogeneous materials, there is need for the determination of effective material properties. To achieve best performance, accurate material property estimation is essential because associated analysis and design for selecting an optimal vol.-fraction depends on its suitability. Various modeling approaches used for FGMs are 1. Rules of mixtures Linear rule of mixtures Harmonic rule of mixtures 2. Variational approach 3. Micromechanical approaches Rules of mixtures employ bulk constituent properties assuming no interaction between phases. This approach derived from continuum mechanics and is free from 3 empirical considerations. In variational approach, variational principles of thermomechanics used to derive the bounds for effective thermophysical properties. Micromechanical approaches include information about spatial distribution of the constituent materials. Standard micromechanical approach is based on concept of unit cell or Representative Volume Element (RVE) to represent the microstructure of composite. 1.7 Critical Elements in a smart structure There are three important components of smart structures, namely Actuators Sensors Control system. 1.7.1 Actuators Actuator is generally the reverse of sensor. It converts electrical inputs to physical (thermal, mechanical, etc) outputs. The ideal mechanical actuator would directly convert electrical input into strain or displacement in the host structure. The principal actuating mechanism of actuators is referred to as actuation strain. 1.7.2 Sensors Sensors are mechatronics devices that can convert analogue physical values into electrical impulses thus informing of their magnitude. The ideal sensor for smart structures converts strain or displacement directly into electrical output. The primary functional requirement of such sensors is their sensitivity to strain and displacement. 1.7.3 Control System Implementing various control methodologies performs the control of intelligent structures. Different type of control strategies are available. 1.7.4 Piezoelectric materials Piezoelectric materials have the ability to generate electric potential in response to applied mechanical stress. 4 This property is exhibited by certain materials like ceramics & some crystals. The piezoelectric effects can be seen as transfer between electrical and mechanical energy. Such transfers can only occur if the material is composed of charged particles and can be polarized. For a material to exhibit an anisotropic property such as piezoelectricity, its crystal structure must have no centre of symmetry. 1.8 Piezoelectric Fiber Reinforced Composites Active control of smart structures depends on the magnitude of electric potential difference for a given mechanical stress. This subsequently depends on the piezoelectric stress/strain constants. The existing monolithic piezoelectric materials being used in smart structures posses low control authority as magnitude. Because, their piezoelectric tailoring of these characteristics of the smart structures. Composites (PFRC) applications. These is stress/strain properties constants may improve are the of small damping Currently, Piezoelectric Fiber Reinforced being effectively composites show used in improved underwater mechanical and medical performance, electromechanical coupling characteristics, and acoustic impedance matching with the surrounding medium over the piezoelectric material alone. 1.9 Motivation of the present work Functionally Graded Materials are a new breed of materials which are the answer to many structural problems demanding self control and flexible characteristics involving mechanical and thermal stresses. The technological implications of this class of materials (FGMs) are immense, as they are especially useful in remote operations, expensive space operations subjected to extreme thermo-mechanical loadings, aerospace skins, protective shields, components in reactor vessels, machine tools, and medical applications, to name only a few. As the advent of steel changed the last century, similarly FGM’s are the materials which will revolutionize the 21st century. These material systems have charecteristics such as thermoelectro-mechanical coupling, functionality, intelligence, and gradation at micro and nano scales. The reliability and integrity of these systems are the main challenges before us. They 5 can be customized to operate under varying conditions covering the whole spectrum of electro-thermo-mechanical conditions. The conditions can vary across a wide range of temperature, magnetic & electric fields, pressure and mechanical load, and/or a combination of two or many. Experimental investigations of both these systems & materials although possible, are prohibitively expensive, and therefore must be complemented with simulations and theoretical analyses. 1.10 Applications of FGM/ smart FGM structures A wide variety of applications exist for smart FGM structures. 1. Aerospace Aerospace skins Rocket engine components Vibration control Adaptive structures 2. Engineering Cutting tools Wall linings of engines Shafts Engine components Turbine blades 3. Nuclear energy Nuclear reactor components First wall of fusion reactor Fuel pellet 4. Optics Optical fiber Lens 5. Electronics Graded band semiconductor Substrate 6 Sensor Actuator Integrated chips 6. Chemical plants Heat exchanger Heat pipe Reaction vessel Substrate 7. Energy conversion Thermoelectric generator Thermoionic converter Fuel cells, solar cells 8. Biomaterials Implants Artificial skin Drug delivery system Prosthetics 9. Commodities Building material Sports goods Car body Casing of various materials Air Conditioning temperature control 7 CHAPTER 2 BACKGROUND AND LITERATURE REVIEW 2.1 General Advanced composite materials offer numerous superior properties to metallic materials, like high specific strength and high specific stiffness. This has resulted in the extensive use of laminated composite materials in aircraft, spacecraft and space structures. In an effort to develop the super heat resistant materials, Koizumi [1] first proposed the concept of FGM. These materials are microscopically heterogeneous and are typically made from isotropic components, such as metals and ceramics. After the concept of FGMs was set by the Japanese school of material science, see e.g. [1] for an earlier contribution, and confirmation of their potentials found even in natural materials [2], several branches of research originated and are still being broadened by research groups all over the world. 2.2 Thermal stress analysis and applications Abrupt transition in material properties of laminated composites across the interface between discrete materials can result in large interlaminar stresses and lead to plastic deformation or cracking. Teymur [2] carried out the thermomechanical analysis of materials, which are functionally graded in two directions, and demonstrated that the onset of delamination could be prevented by tailoring the microstructures of the composite piles. Thus, the use of FGM may become an important issue for developing advanced structures. Feldman and Aboudi [3] studied the elastic bifurcational buckling of functionally graded plates under in-plane compressive nonuniform distribution load. They concluded that with optimal of reinforcing phases, the buckling load can be significantly improved for FG plate over the plate with uniformly distributed reinforcing phase. Mian and Spencer [4] derived the exact solutions for functionally graded plates with zero surface traction. Gasik [5] developed an efficient micromechanical model for FGMs with an arbitrary non-linear 3D-distribution of phases. This model has been reported to provide accurate estimates of the properties of the FGMs. The model is also capable of computing 8 thermal stresses, evaluating dynamic stress/strain distribution and inelastic behavior of FGMs. Praveen and Reddy [6] investigated the nonlinear thermoelastic behavior of functionally graded ceramic metal plates. 2.3 Fracture and creep analysis In 2000, Wang et al.[ 7] proposed a method to determine the transient and steady state thermal stress intensity factors of graded composite plate containing noncollinear cracks subjected to dynamic thermal loading. Yang [8] presented an analytical solution for computing the time-dependent stresses in FGM undergoing creep. Yang and Shen [9] studied the dynamic response of initially stressed functionally graded thin plates subjected to partially distributed impulsive loads. 2.4 Exact and analytical solutions An elasticity solution for functionally graded beams was provided by Sankar [10] in which the beam properties are graded in the thickness direction according to an exponential law. Batra and Vel [19] have presented the exact solutions for thermoelastic deformations of thick FG plates subjected to both thermal and mechanical loads. Woo and Meguid [11] presented an analytical solution for the large deflections of plates and shallow shells made of FGMs under the combined action of thermal and mechanical loads. The exact solutions for thermoelastic deformations of thick FG plates subjected to both thermal and mechanical loads have been presented by Batra and Vel [12]. Zhong and Shang [22] presented three dimensional exact analysis of a simply supported functionally gradient plate. 2.5 Vibration and control Loy [13] studied the vibration of cylindrical shells made of a functionally graded material, which was composed of stainless steel and nickel. Aboudi et al. [14] further developed a more general higher-order theory for functionally graded materials and illustrated the utility of functionally graded microstructures in tailoring the behavior of structural components in various applications. 9 2.6 Smart structures and Functionally Graded Materials The continuing research on materials being lightweight yet having high strength & flexibility, which would constitute self-controlling & self-monitoring capabilities. For such requirements piezoelectric materials are essential. They are also the main constituents of actuators & sensors mounted or embedded in the system. Such structures capable of demonstrating self-control and adaptability are called smart structures. The concept of developing smart structures has been extensively used for active control of flexible structures during the past decade. Reddy and Cheng [20] presented three dimensional solutions of smart functionally graded plates. He and Liew K M [21] presented active control of FGM plates with integrated piezoelectric sensors and actuators. Very recently, Huang and Shen [18] investigated the dynamics of a functionally graded (FG) plate coupled with two monolithic piezoelectric layers at its top and bottom surfaces undergoing nonlinear vibrations in thermal environments. 2.7 Piezoelectric Fiber Reinforced Composite (PFRC) The major bottleneck in the development of smart structures is the small magnitude of control exhibited due to the small strain in piezoelectric. Hence the structure cannot demonstrate sufficient amount of control and hence damping (In vibration damping systems) and the flexibility of the system is also not up to the mark. The solution is improving the piezoelectric stress/strain coefficients which will increase t hei r control authority and hence the damping (By decreasing the vibration amplitude as well as oscillation decay time. In an effort to tailor the piezoelectric properties, Mallik and Ray [23] proposed the concept of longitudinally Piezoelectric Fiber Reinforced Composite (PFRC) materials and investigated the effective mechanical and piezoelectric properties of these composites. The main concern of their investigations was to determine the effective piezoelectric coefficient (e31) of these new concept PFRC materials, which quantifies the induced normal stress in the fiber direction due to the applied electric field in the direction transverse to the fiber direction. They observed that this effective piezoelectric coefficient was significantly larger than the corresponding co-efficient of piezoelectric material of the fibers. Ray and Sachade [24] have recently derived the exact solutions for 10 the linear analysis of the simply supported functionally graded plates integrated with a layer of this new Piezoelectric Fiber Reinforced Composite (PFRC) material. Subsequently, they also developed a finite element model for the linear analysis of simply s upport ed functionally graded plates integrated with the layer of this PFRC material [25]. Still breakthroughs are awaited in the field of functionally graded shell structures subjected to combined electromechanical loading under temperature field 2.8 Objectives of present work The objective of the present work has been to: Develop a finite element code for smart functionally doubly curved shells subjected to a coupled electro-thermo-mechanical loading integrated with layers of the piezoelectric sensor -actuator patches on its surface. Develop a finite element code to determine the free vibrations of a FG layer. To study the effect of grading on the static response and fundamental frequency of a FG layer. 2.9 Layout of the thesis The thesis is organized in various chapters as mentioned below. Chapter 1 gives an introduction to FGM and smart FGM structures, their advantages over conventional laminated composites. Chapter 2, is an extensive literature review on the developments of theoretical analysis of functionally graded materials and their finite element modes. The literature review concerning the use of FGM structures as smart structures is also discussed. New class of sensor-actuator (PFRC) for smart control is also studied. Chapter 3 includes the determination of effective properties of a PFRC using micromechanical analysis is presented. Chapter 4 includes the formulations for static and free vibration analysis for the functionally graded doubly curved shells. 11 Chapter 5 Covers the numerical examples to validate the models developed for static analysis. Few examples are given for electro-thermo-mechanical analysis of smart FGM structures. Subjected to similar conditions, the performance of plate with the shell element is compared. The performance of piezoelectric patches and PFRC for deflection control is compared. Effect of gradation on the static and frequency response is studied. Conclusions from the investigations of the finite element analysis of smart FGM structures, the proposed work to be done in next phase is presented in Chapter 6. 12 CHAPTER-3 EFFECTIVE COEFFICIENTS OF PIEZOELECTRIC FIBERREINFORCED COMPOSITES 3.1 Assumptions involved in this analysis Fibers in the to-be developed composite are parallel and continuous Fiber and composite are linearly elastic. Matrix material is piezoelectrically inactive. Fiber and matrix are bonded firmly. A constant electric field exists in a direction at right angles to the fiber direction. (Made using Paint) 13 3.2 Strength of material approach The micromechanical analysis is confined to a Representative element (RVE) that includes both fiber and the surrounding matrix. The piezoelectric fibers are oriented longitudinally, i.e. along the global x-axis. Fig.3.2 A longitudinal cross-section of a representative volume of PFRC(made usingPaint) The constitutive relations for the fibers (piezoelectrically active) are 14 And those for the Matrix are As there is perfect bonding assumed, therefore the strains are same in x-direction Also, lateral stresses are same in the y and z direction By rule of mixtures the lateral strains in y and z direction can be written as vf , vm are the volume fractions of fiber and matrix, respectively. From eq. (3.16) σ ym = σ yp 15 Similarly we have σzm = σzp from eq (3.16). Equating eq. (3.3) and (3.10) and using eq (3.15), and after rearranging the terms where 16 Now, axial equilibrium of the composite requires that the composite stresses in the axial direction can be written using the rule of mixture as Putting (3.1) and (3.8) in the above equation, and rearranging If we define the resultant coefficients of composite as Then on comparing the coefficients of eq. (3.32) and (3.34) 3.3 Effective coefficients of PFRC layer Resultant effective coefficients of a PFRC layer are written as 17 Also, putting eq. (3.20) and (3.21) in (3.2) and using and equating the coefficients, the rest of the effective coefficients of a PFRC layer are obtained as Also, resultant permittivity in the PFRC composite can be written using the rule of mixtures as Putting the values of Dxp and D x m from eq (3.17) and (3.14) and using eqs (3.17), (3.20) and (3.21) and after rearranging the terms, effective permittivity of the PFRC composite are obtained as 18 Thus effective coefficients of a PRFC are determined in the above micromechanical analysis, which would be used in the present work. They can be used now to compare their effectiveness in controlling the deflections of a mechanical structure, as compared to existing monolithic PZT actuators. 19 CHAPTER 4 FINITE ELEMENT MODELLING OF SMART FGM SHELL 4.1 Introduction Study of physical systems frequently results in partial differential equations, which either cannot be solved analytically, or lack an exact analytic solution due to the complexity of the boundary conditions or domain. For a realistic and detailed study, a numerical method must be used to solve the problem. The finite element method is often found the most adequate. Over the years, with the development of modern computers, the finite element method has become one of the most important analysis tool in engineering. It has penetrated successfully many areas such as heat transfer, fluid mechanics, electromagnetism, acoustics and fracture mechanics. Finite element packages are now widely available on personal workstations. Studying functionally graded materials require a numerical technique to solve, as the variation of material properties would be very difficult to analyze analytically. As FGM materials are used primarily at high temperature environments, therefore they may be of arbitrary shape and sizes, geometry and loading thus making it almost impossible to obtain analytical or exact solutions for the real life conditions. The finite element method is very much suited for the analysis of plates and shells of general shape because of its flexibility in accounting for arbitrary geometry, loadings and variation in material properties. In finite element analysis, the structure is subdivided into a finite number of elements of simple geometry, and the physical fields are interpolated inside these elements using shape functions and nodal values of the field variables. In this work, the equations of motion are described using a first-order shear deformation theory (FSDT) based on the Reissner – Mindlin assumptions. Eight- noded serendipity plate element have been used. Linear elastic behavior of materials is assumed throughout this analysis and temperature field is assumed to be known. The top and bottom surfaces are bonded with piezoelectric films 20 4.2 Geometry and kinematics of doubly curved shell element 4.2.1 Assumptions in the model development In developing the working model we have taken into account some assumptions They are: FGM shell is assumed to be graded in thickness direction, FGM shell is isotropic in other two directions. Linear elasticity is assumed in the formulation The deformations follow Mindlin’s hypothesis, i.e. normal to the middle surface only of the shell before deformation may not remain normal after deformation but remains straight and inextensional. The in-plane displacement components are assumed to vary linearly along the thickness direction to yield constant transverse shear strain. The piezoelectric patches are thin and are perfectly bonded to the FGM layer. 4.2.2 Shell geometry considerations The present work deals with regular doubly curved shells where the shell midsurface Ω ϵ R3 has been mapped into parametric space (α 1, α 2 )ϵ A:R 2 →R 3 through a suitable exact parameterization. Two independent coordinates (α 1, α 2 ) parametric space have been considered as the midsurface curvilinear coordinates of the shell as shown in Fig.4.3 The normal direction coordinate to the middle surface of the shell has been represented by ζ. The reference surface or shell midsurface thus defined can be described as 21 For the analysis of the shell the Lame’s parameters neglecting the trapezoidal effect of the shell cross-section can be computed as Fig 4.1 A layered composite doubly curved shell element[39]. (4.1) The comma denotes the partial differentiation. Unit tangent vectors of the midsurface can be expressed as (4.2) The unit normal vector to the tangent plane of any point on the reference surface has been computed using the following relation (4.3) 22 The physical components of the normal and twist curvatures of the shell midsurface can be expressed as: (4.4) 4.2.3 Discretization of shell global space to isoparametric space We have taken into account the parametric space A as an assembly of sub domains or elements which are quadrilateral in nature. Here sample space A is summation of individual elements in the parametric space. We have approximated any point within an element in the parametric space by performing‘isoparametric mapping’.The concept used is(ξ,η) є [1,1]Х[-1,1]|→Ae as shown in Fig 4.4. so the curvilinear coordinates (α1,α2) of any point within an element [36] may be expressed as follows: Figure4.2(a). Global space x, y, z (b) parametric space α1,α2 ; and (c) isoparametric spaceξ,η[39] 23 4.2.4 Displacement field and strains for shell element The displacement components on shell midsurface S at any point within an element may be expressed as (4.5) Here ui,vi,Φ1i,Φ2i are the unknown displacement components of the ith node. Ni (ξ,η) is the interpolation function corresponding to the ith node of an element and ne is the number of nodes per element. In this analysis, programming code is developed in such a way that the interpolation functions are that of a Serendipity element[39] 4.2.5 Isoparametric Finite Element approximation of displacement field and electric field for shell element The strain vector of a doubly curved shell may be expressed as (4.6) (4.7) (4.8) 24 (4.9) (4.10) (4.11) (4.12) (4.13) 25 (4.14) The stress-strain relationship becomes (4.15) Where [D] is the rigidity matrix 4.2.6 Jacobian matrix (Transformation matrix) (4.16) (4.17) (4.18) 26 4.3 Governing differential equations Equation of equilibrium (4.19) Equation of electrostatics (4.20) One dimensional steady state heat transfer coefficient (4.21) Finite element analysis can be done either, by finding weak form of above governing differential equations and then extremizing the functional obtained w.r.t elemental displacement vector {d e }or from the virtual work principle 4.4 Static finite element equations (4.22) 27 4.4.1 Mechanical strain energy (4.23) (4.24) Putting in eq (4.23) [39] (4.25) After putting FE approximation for displacement vector eq.(4.55) and using FSDT theory eq.(4.46-4.48) (4.26) (4.27) 28 (4.28) (4.29) 4.4.2 Electrical potential energy Using constitutive relations, strain displacement and electric field electric-potential relations, the element electrical energy can be written as (4.30) (4.31) (4.32) 29 4.4.3 Work done by the external forces and electrical charge The virtual work done by the external forces due to the applied surface traction and the applied electrical charge density is given by (4.33) where {f(x,y)} and {g(x,y)}the surface force intensity and surface electrical charge density respectively. Ω1 and Ω2 are the surface areas where the surface forces and electric charge are applied, respectively. Discretisizing above equation (4.34) The work done by the body force and point forces are not considered for simplicity. Substituting the elastic strain energy eq and electrical potential energy eq. in internal potential energy eq (4.35) Substituting the internal potential energy and the external virtual work done in total potential energy and setting its first variation to zero, the following system of equations for the element are obtained[39]. . 30 (4.36) where the superscript e refers to the parameter at the element level and [K] matrices with subscripts uu , uφ , φu , φφ are defined below. (4.37) (4.38) (4.39) (4.40) The element mechanical force {Fe} and {NMTe} in the eq and the element electrical force vector {Qce} in eq are defined as (4.41) (4.42) (4.43) 4.5 Dynamic finite element equations The dynamic equations of a piezo-laminated composite shell can be derived from the Hamilton’s principle 31 (4.44) where Le represents the Lagrangian, and δW e is the virtual work of external forces The Lagrangian is to be properly adapted in order to include the contribution from the electrical field besides the contribution from the mechanical field Le=Te–Ue (4.45) Above eq. can be further expressed by (4.46) in which T is the kinetic energy and can be written as (4.47) d is the velocity vector and ρ is the mass density matrix. t1and t2 define the time interval. 1 All variations must vanish at t = t1 and t = t2 .The individual parts of the Hamilton equation (Eq. (4.109)) can be written as Kinetic energy (4.48) On integrating by parts (4.49) As all variations vanish at t t1 and t t2 32 (4.50) (4.51) The potential energy terms and virtual work done by external forces can be written from that of static situation, as they would remain the same (4.52) Putting eq. (100) and eq. (101) in Hamilton’s eq. (94) (4.53) which must be verified for any arbitrary variation of the displacements and electrical potentials compatible with the essential boundary conditions. For an element above eq. can be written as (4.54) 33 Where (4.55) After assembly of the elemental matrices eq. (4.119) - (4.120), the global sets of equations are obtained as follows (4.56) In this work, the plate or shell is assumed to be of constant thickness and isotropic in the plane perpendicular to the thickness direction. Structural stiffness can be separated into bending stiffness and transverse stiffness matrices as they are not coupled and thus are independently calculated. [39] (4.57) (4.58) on converting to natural coordinates, (4.59) (4.60) 34 A, B, D are given by eq. (4.27).For a FG shell (4.61) (4.62) (4.63) (4.64) And E(z) represents the elastic Young’s modulus and is function of z .v is poison’s ratio and is assumed constant throughout the thickness. On integrating we get the effective bending stiffness matrix. For power law, variation (4.65) (4.66) 35 (4.67) (4.68) (4.69) (4.70) (4.71) 4.6 Thermal load (4.72) 36 4.7 Piezoelectric patches Uniform electric field and displacement across the thickness and aligned on the normal to the mid-plane (direction z or ). It is assumed that no shear strain is induced by a transverse electric field, which is the case for most commonly used piezoelectric materials in laminar design (PZT and PVDF). If constant potential across each element is assumed, one degree of freedom for electrical potential per layer is defined [35]. (4.73a) ,(4.73b) Variation of electric potential function across the thickness may be considered linear, then at any point, if potential is taken as a nodal variable [25]. (4.74a), (4.74b) 4.8 Thermal analysis to determine temperature distribution in the thickness direction For the evaluation of temperature induced load N T and moment M T it is required to determine the temperature distribution T (ζ,η,ξ) subjected to Dirichlet boundary conditions. Since present work deals with transversely isotropic material, therefore temperature will be a function of z only. The temperature distribution can be obtained by solving one dimensional steady state heat conduction equation 37 (4.75) Closed form of equation is not possible as k is also a function of thickness coordinate. Hence, it solved using Ritz method with Langrage polynomials. Temperature distribution is approximated by trial functions as a sixth-order polynomial [31] (4.76) This results in pretty good approximation without excessive computational overheads. The unknown parameters are calculated from the boundary conditions. 4.9 Element mass matrix Element mass matrix in an element is defined as (4.77) (4.78) (4.79) ρk is the density of the kth lamina. 38 CHAPTER-5 RESULTS AND DISCUSSIONS 5 Validation of Finite Element Code of doubly curved shell element Doubly curved shell is obtained from the surface of a sphere. The dimensions of the spherical shell obtained after cutting from a sphere are as mentioned. 5.1 Static mechanical shell element In the element the plate element if its radius of curvature is very high as compared to its dimensions. Due To lack of existing literature on FG shells, the response of the shell element is compared with that of FG plate. To achieve this, very high radii (of the order of 106 meters) has been taken and the response obtained has been compared with the corresponding response of the plate element under same loading, geometry, boundary conditions, gradation and material properties. The lower shell surface is assumed to be aluminum while the top surface is assumed to be zirconia. Material properties vary with the power law defined in chapter 5. P(z)=(P2-P1){(2z+h)/2h}λ+P2 and the values of λ=0,1,2,106, assuming (∞=106), are considered. Physical material properties are given in table 5.1. The dimensions of the shell Length a=200mm, width b=200mm and thickness h=10mm The radius of curvature R1, R2=106 Material Properties Aluminum Zirconia Young’s Modulus 70GPa 151GPa Poisson’s Ratio 0.3 0.3 Thermal Conductivity 204W/mK 2.09W/mK Thermal Expansion 23x10-6/oC 10x10-6/oC Table 5.1: Material properties of FG shell 40 Boundary conditions applied Simply supported boundary conditions: At x=0 and x=a, u=0, w=0, ϕy=0 for all nodes in that particular plane. At x=0 and x=a, u=0, w=0, ϕx=0 for all nodes in that particular plane. Uniform load q given by P= (a4q/t4Ebottom) where P is the load applied along z direction. Power Load parameter -6 Center deflection w(in mm) of present shell element -1.23576 Center deflection w(in mm) Corce, Venini [28] -1.2 coefficient P=(a4q/t4Ebottom) -10 -0.205960 -2.05 -13 -2.67744 -2.7 -6 -1.86573 -1.75 -10 3.10955 -3.15 -13 -4.04243 -4.09 -6 -2.6653 -2.2 -10 4.44274 -4.45 -13 -5.77551 -5.86 λ 0 2 106(∞) Table 5.2: Comparison of center displacement of doubly curved shell (large radii), With a plate element using (4x4) elements under mechanical loading only. Since the results for shell and plate agree well, within limits, as shown in Table 5.2, therefore the element predicts the mechanical behavior accurately. 41 5.2 Static thermo-mechanical analysis of the shell element In addition to a uniformly distributed mechanical normal load on the top surface, the shell has been subjected to a thermal field where the ceramic rich top surface is held at 3000C ant the metal rich bottom surface is held at 200C. a stress free temperature of 00C is assumed. Power Load parameter coefficient P=(a4q/t4Ebottom) deflection λ Center w(in Center mm) present 0 2 5 106(∞) deflection of shell w(in mm) Corce, Venini element [28] 0 1.45186 1.3 -5 0.422042 0.43 -10 -0.607756 - 0 1.02927 0.998 -5 -0.525495 -0.5 -10 -2.08026 - 0 1.32473 1.3 -5 -0.373779 -0.39 -10 -2.07229 - 0 2.30241 2.46 -5 0.208969 0.2 -10 -2.01239 - Table 5.3: Comparison of center displacement of doubly curve (large radii), with a plate element using (4x4) elements under thermo-mechanical loading Above results in Table5.3 show that the complete thermo-mechanical modeling of the doubly curved FGM shells are accurate. It can be seen that the response of graded shells is not intermediate to the metal and ceramic shells. The center deflections of both the metallic and the 42 ceramic shells are higher then those of the graded shells. This is in agreement with the result obtained for FG shells. 5.3 Validation of electromechanical coupling of the piezoelectric materials using doubly curved shell element 5.3.1 PFRC actuator integrated on the surface of a doubly curved shell FG shell, as in plates is an exponential function of thickness (z), measured from the mid plane of the FG layer, and is given by E (z ) = E1eλ(z+h/2) Where, E1=200GPa and μ=0.3 in which μ is the Poisson’s Ratio of the FGM. λ is the exponential gradient parameter depending on the ratio of Young’s modulus at the top to that at the bottom. Dimensions of shell structure, h=3 mm for FG plate and h=250μm of the PFRC layer. Length a=60mm The radius of curvatures of the shell element R1, R2=106 Fiber/ C11 C12 C13 C33 C44 e31=e32 e33 ϵ33 Matrix GPa GPa GPa GPa GPa GPa GPa GPa PZT-5H 151 98 96 124 14 -5.1 27 13.27x10-9 Epoxy 3.86 2.57 2.57 3.86 2.57 0 0 0.079x10-9 Table 5.4: Material properties of fibers and matrix of PFRC layer The piezoelectric fiber and the matrix of the PFRC layer are made of PZT5H and epoxy, respectively. The elastic and piezoelectric co-efficient for piezoelectric fiber and matrix of the 43 PFRC layer are given in Table-5.4. Effective material and piezoelectric constants are obtained by using the micro-mechanics model derived earlier in chapter-2, and are used for computing the numerical results. Fiber volume fraction vf =0.4 is taken for numerical analysis. Power law Potential s=a/h=10 s=a/h=10 applied coefficient λ on PFRC Surface ϕ wХ10 wХ10 -8 (shell) -8 (Ray & Sachade [25]) Φ=nodal wХ10 -8 (shell) Φ=nodal wХ10 -8 (Ray & Sachade [25]) dof dof λ=767.528 λ=767.528 -100 -1.55353 -1.623291 -6.47042 -6.5976096 0 -0.00404 -0.0089736 -0.13117 -0.1401312 100 1.54542 1.6053324 6.20804 6.3173376 -100 -26.275 -28.455 -114.508 -114.9024 0 -0.0544 -0.0820716 -1.20644 -1.2778944 100 26.2037 28.2917 112.1 112.3488 Table 5.5: Center deflection of the FGM shell bonded to a curved PFRC actuator on its top It could be observed that the response of the smart FG shell match with that of the plate element and that in [25], in the limit of large radius. Thus the formulation of the shell element for the functionally graded material is correct and can be used to determine static response of FG materials. 44 5.4 Variations in response due to various types of loadings r/a = 1,2,5,10,100,200 a/h = 10,100 Special Case that we have considered h=3.5x10-3, a=3.5x10-1,r/a=10,a/h=100,Distributed loading in z-direction only. 5.4.1 Variations in response due to pure thermal loading Serial no λ Tfree_surface 0 C Tbottom 0 Ttop 0 C C Mid-surface Sensor Voltage Deflection Volts (in meter) 1 767.582 0 300 25 0.0031652m 168.78 2 767.582 25 300 30 0.0031701m 173.45 3 767.582 30 250 30 0.0031801m 161.5 4 767.582 10 280 35 0.004529m 201.025 5 767.582 20 300 35 0.004422m 205.57 6 767.582 25 300 30 0.004371m 189.2 Table 5.6: Variations during Thermal loading On subjecting the structure to different temperature conditions, we find a regular variation in the mid-surface deflection and induced voltages in the nodes. Studying these responses we can find the range of temperatures to which the layers are subjected to. This will give us an idea about the temperature range in which the structure can have maximum performance and optimized results. 45 5.4.2 Variations in response due to pure mechanical loading Serial no Mechani -cal Loading N/mm Tfree_surface 0 Tbottom 0 C Ttop 0 C C Angle of Piezoelctreic Fiber Mid-surface θ (in meter) 2 Deflection Sensor Voltage Volts (in radian) 1 -100 0 0 0 0 -2.982x10-6m 0.0193 2 -80 0 0 0 0 -1.91176x10-6m 0.1243 3 -50 0 0 0 0 -1.491x10-6m 0.0096 4 -100 0 0 0 30 -2.979x10-6m 0.0192 5 -100 0 0 0 45 -2.9839x10-6m 0.0191 6 -100 0 0 0 60 -2.2984x10-6m 0.01911 Table5.7: Variations during pure Mechanical Loading When the structure is subjected to mechanical loading, due to deflections at the mid-surface of different nodes different voltages are induced. We note down these deflections and corresponding voltages for further in-depth study. We also tabulate the midpoint deflection of the central node and the highest induced voltage and try to find out if a pattern is present. 46 5.4.3 Variations in response due to Thermo- mechanical loading Thermo-Mechanical Loading Serial Mechani- no cal Tfree_surface Tbottom 0 Loading C 0 Ttop 0 C C λ Mid-surface (ratio) Deflection (in meter) Sensor Voltage Volts N/mm2 1 -100 0 300 35 767.582 0.00521m 224.53 2 -100 10 300 35 767.582 0.00481m 215.8373 3 -100 30 300 35 767.582 0.004025m 198.362 4 -50 0 300 35 767.582 0.005211m 224.54 5 -50 10 300 35 767.582 0.004817m 215.827 Table5.8: Variations during Thermo-Mechanical Loading Above we are trying to build a relationship between the different conditions that affect the final response to thermal and mechanical loading taken simultaneously. The values obtained from simulation tell us about the direct response of these parameters to the response. 47 5.4.4 Variations in response due to Electro-Thermo- mechanical loading Sl no Mechanical Loading N/mm2 Tfree_ Ttop Tbottom surface 0 C 0 C 0 Applied actuator Voltage Volts Angle of Piezoelectric Fiber C λ (ratio) Midsurface Sensor Voltage deflection Volts (in meter) θ (in radian) 1 -100 25 30 300 0 0 767.58 0.0409 202.13562 2 -100 25 30 300 20 0 767.58 0.004 202.132 3 -100 25 30 300 50 0 767.58 0.004 202.08 4 -100 25 30 300 100 0 767.58 0.0041 202 5 -100 20 35 300 20 0 767.58 0.0042 157 6 -100 20 35 300 50 0 767.58 0.0042 147 7 -100 25 30 300 50 30 767.58 0.0042 139 8 -100 25 30 300 20 30 767.58 0.00409 200.14 9 -100 25 30 300 50 60 767.58 0.0041 190 10 -100 25 30 300 20 60 767.58 0.0041 137 Table5.9Variations during Electro-Thermo-Mechanical Loading Applying all three conditions simultaneously we try to reach a conclusion on how to optimize the deflections and voltages induced. The results obtained by changing the three loading parameters give us a better understanding of the weightage of each of the parameters in determining the overall response. 48 5.5 Scope for Future Work Smart materials are all set to occupy the center stage. In the consistent efforts to develop them we can recommend some measures which are being implemented throughout by scientists but is out of scope for us due to constraints in infrastructure and laboratory equipments. Still we propose the following 1. Joining the sensors and actuators through a control circuit will result in reducing the deflection and hence stresses produced in smart structures. This control setup tries to minimize the deflection in the structure. The underlying principle behind this is that every deflection causes a simultaneous change in voltage. Sensing this change if we apply a somewhat opposite voltage through the control circuitry this deflection would be minimized as a contradictory effect is produced. 2. 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