A validated simulation methodology for determining single lap shear allowable strength in thermoplastic polymer composites

Abstract

While several modeling approaches exist to simulate the strength of single lap shear configurations, their application to obtaining design allowables for thermoplastic composites remains underexplored. This paper addresses this gap by presenting a novel methodology for the forward propagation of parameter uncertainty using advanced finite element models specifically tailored for thermoplastic carbon fiber composites. The proposed approach goes beyond traditional methods by integrating advanced damage models and a structured validation process, supported by an extensive experimental test campaign. We demonstrate the feasibility of determining design allowables through simulation by examining the influence of batch size on both the validation process and the prediction of allowable strength. Our findings provide new insights into the propagation of uncertainties in the context of composite material design, showing that it is possible to achieve reliable design allowables through simulation, which can significantly accelerate the development of new components while maintaining high safety standards