A New Method To Predict Damage To Composite Structures Using Convolutional Neural Networks
A New Method To Predict Damage To Composite Structures Using Convolutional Neural Networks
Article
A New Method to Predict Damage to Composite Structures
Using Convolutional Neural Networks
Laurent Mezeix 1 , Ainhoa Soldevila Rivas 2 , Antonin Relandeau 2 and Christophe Bouvet 3, *
1 Faculty of Engineering, Burapha University, 169 Long-Hard Bangsaen Road, Chonburi 20131, Thailand;
[email protected]
2 INSA Toulouse, 135 Avenue de Rangueil, CEDEX 4, 31077 Toulouse, France;
[email protected] (A.S.R.); [email protected] (A.R.)
3 INSA/ISAE-SUPAERO/IMT Mines Albi/UPS, Institut Clément Ader (CNRS UMR 5312),
Université de Toulouse, 10 av. E. Belin, CEDEX 4, 31055 Toulouse, France
* Correspondence: [email protected]
Abstract: To reduce the cost of developing composite aeronautical structures, manufacturers and
university researchers are increasingly using “virtual testing” methods. Then, finite element methods
(FEMs) are intensively used to calculate mechanical behavior and to predict the damage to fiber-
reinforced polymer (FRP) composites under impact loading, which is a crucial design aspect for
aeronautical composite structures. But these FEMs require a lot of knowledge and a significant
number of IT resources to run. Therefore, artificial intelligence could be an interesting way of sizing
composites in terms of impact damage tolerance. In this research, the authors propose a methodology
and deep learning-based approach to predict impact damage to composites. The data are both
collected from the literature and created using an impact simulation performed using an FEM. The
data augmentation method is also proposed to increase the data number from 149 to 2725. Firstly,
a CNN model is built and optimized, and secondly, an aggregation of two CNN architectures is
proposed. The results show that the use of an aggregation of two CNNs provides better performance
than a single CNN. Finally, the aggregated CNN model prediction demonstrates the potential for
CNN models to accelerate composite design by showing a 0.15 mm precision for all the length
Citation: Mezeix, L.; Rivas, A.S.;
measurements, an average delaminated surface error of 56 mm2 , and an error rate of 7% for the
Relandeau, A.; Bouvet, C. A New
prediction of the presence of delamination.
Method to Predict Damage to
Composite Structures Using
Keywords: Convolutional Neural Network (CNN); carbon fiber-reinforced polymer; composite;
Convolutional Neural Networks.
Materials 2023, 16, 7213. https://
impact; impact damage
doi.org/10.3390/ma16227213
andhasCompression
led to standards forImpact
After composite
[5]. coupons
Figure 1under low‐velocity/low‐energy
illustrates the impact geometry impact [13] by
defined
and Compression After Impact [5]. Figure 1 illustrates the impact geometry defined by
the standard ASTM D7136 and various types of impact damage corresponding to different
the standard ASTM D7136 and various types of impact damage corresponding to different
levels of impact energy [2]. In the initial stage, damage manifests as small matrix cracks as
levels of impact energy [2]. In the initial stage, damage manifests as small matrix cracks
the impact causes minimal denting. As the impact energy increases, delamination occurs,
as the impact causes minimal denting. As the impact energy increases, delamination oc‐
leading to larger dents. In the second stage, all three types of damage—matrix cracks,
curs, leading to larger dents. In the second stage, all three types of damage—matrix cracks,
delamination, and fiber breakage—can occur, making visual inspection easier due to the
delamination, and fiber breakage—can occur, making visual inspection easier due to the
larger
largerdent
dentsize
size(dent
(dentdepth
depth and
and diameter). Thepresence
diameter). The presenceofoffiber
fiber breakage
breakage in in
thisthis stage
stage
aids in achieving more accurate inspection results. However, this can negatively
aids in achieving more accurate inspection results. However, this can negatively impact impact
thethe
material’s
material’sresidual
residual strength afterthe
strength after theimpact,
impact, contributing
contributing to complexity
to the the complexity
of the of
in‐the
interaction between various damage types during an impact event. Finally,
teraction between various damage types during an impact event. Finally, in the third in the third
stage, the damage becomes visible to the naked eye as perforation
stage, the damage becomes visible to the naked eye as perforation occurs. occurs.
Figure (a)(a)Schematic
1. 1.
Figure Schematicofofimpact
impact test
test setup, and(b)
setup, and (b)different
differentimpact
impactdamage
damage stages
stages with
with respect
respect to to
thethe impact
impact energyand
energy andpermanent
permanentindentation
indentation size.
size.
dedicated to three key factors: stacking sequence, impactor shape, and impact energy. The
outcomes of their study revealed that characteristics such as local volume, dent surface
gradient, and pure dent depth could effectively serve as indicators for characterizing
internal damage in CFRP laminates.
The utilization of a machine learning-based approach holds immense potential in
expediting the design process for optimal composite materials, resulting in significant
time and resource savings [36]. The prediction of composite properties takes advantage
of CNN models. The thermal conductivity properties of particle-filled 3D composites
were predicted thanks to 2D CNN models using 3000 multiple cross-section images as the
input [37]. The results showed that the use of five layers instead of three layers improved
the accuracy of the CNN model. The elastic properties of composite materials, E11 , E22
and G12 , were predicted using a CNN model [38]. In order to create the dataset, the values
corresponding to these properties were generated using an FEM. To address the significant
computational resource challenge associated with generating training data, an innovative
data augmentation scheme was introduced that enabled an increase in the dataset size from
9000 to 4.6 million samples. The results showed that the test error decreased from 2.4% to
0.4%. CNN models have been successfully used to predict the properties of composites
beyond the elastic regime, i.e., crack propagation [39]. An FEM was used to obtain training
data consisting of 26,000 configurations. Crack propagation under the quasi-static frac-
ture of elastic solids was simulated using a hybrid formulation, and the elastic modulus,
strength, and toughness were obtained from stress–strain curves. The results showed
that CNN exhibited better performance than traditional models, i.e., linear regression and
random forest. Stress–strain curves hold significance as they depict a material’s mechanical
characteristics, outlining vital traits like the elastic modulus, strength, and toughness. The
computational intensity escalates when generating these curves through numerical tech-
niques like the finite element method (FEM), particularly when encompassing the complete
failure trajectory of a material. The amalgamation of Principal Component Analysis (PCA)
and Convolutional Neural Networks (CNN) has been employed to forecast the complete
stress–strain curve of composite failures that extend beyond the elastic limit [40]. Using an
FEM, a dataset containing 100,000 distinct composite microstructures and their correspond-
ing stress–strain curves were created. This dataset was then utilized for both training and
evaluating the performance of the model. The results showed a mean absolute error of less
than 10%, demonstrating the robustness of the model. A comprehensive examination of
an ANN in the modeling of composite materials was performed [41]. A large number of
potentials used was identified: metamaterials [42–44], the mechanical behavior of yarns
in textile composites [45], and the shape/size optimization of composite structures [46].
Finally, ANN models hold the potential to address a wide array of challenges, includ-
ing unveiling unfamiliar physical principles and expediting computer simulations for
composite materials.
In this work, CNN models to predict low-velocity/low-energy impact damage to FRP
composites are explored. Initially, the data collection and preparation and the finite element
procedure employed to acquire the training data for the CNN models are discussed. Then,
two different CNN models are developed and optimized. Finally, the two CNN models’
results and validation are detailed and their performances are compared and discussed.
2. Methods
The approach to predicting impact damage to FRP composites used in this study can
be summarized as follows (Figure 2):
Data: Data collection and creation, followed by data augmentation and dataset con-
struction.
Training: Building, training, and validation of CNN models.
Prediction: Use of optimized CNN model to predict the impact damage to composites.
Materials 2023, 16, x FOR PEER REVIEW 5 of 20
Data: Data collection and creation, followed by data augmentation and dataset con‐
struction.
Materials 2023, 16, 7213 Training: Building, training, and validation of CNN models. 5 of 18
Prediction: Use of optimized CNN model to predict the impact damage to compo‐
sites.
utilized
surfaceon of the
thelower surface
laminate of the
to fix the out-of-plane
laminate to fixdisplacement.
the out‐of‐plane displacement.
Geometry
Figure3.3.Geometry
Figure of of
thethe numerical
numerical model.
model.
InInthis
thisfirst
first analysis,
analysis, anan FEA
FEA model
model waswas
usedused to determine
to determine the impact
the impact energy
energy required
required
to reach the critical force avoiding delamination. Indeed, even though a lot of
to reach the critical force avoiding delamination. Indeed, even though a lot of complex complex
and relevant FEMs exist in the literature in order to simulate the damage that develops in
composite structures during impact loading [1–7], the objective is to evaluate the ability
of the AI to predict impact damage and its detectability. The critical force necessary to
induce the beginning of delamination at the mid‐thickness of the laminate under a mode
II fracture is obtained using [6]:
Materials 2023, 16, 7213 7 of 18
and relevant FEMs exist in the literature in order to simulate the damage that develops in
composite structures during impact loading [1–7], the objective is to evaluate the ability
of the AI to predict impact damage and its detectability. The critical force necessary to
induce the beginning of delamination at the mid-thickness of the laminate under a mode II
fracture is obtained using [6]:
8π 2 Eh3
Pc2 = G I Ic (1)
9(1 − µ2 )
where E and v are the equivalent in-plane modulus and Poisson ratio for the laminate,
and h is the laminate thickness. GIIc is the fracture toughness in mode II of the composite
laminate and is taken to be equal to 1.5 N/mm [58]. This value depends on the composite
material, but in this first approach, this value was kept constant in order to highlight the
effect of the stacking sequence on the impact damage. As no damage was simulated, a
simple elastic model was used in order to easily and quickly generate additional data to
feed the AI, and linear elastic properties of unidirectional T700 carbon/epoxy ply were
chosen (Table 2).
Properties
Tensile modulus (GPa) 135
Tensile strength (MPa) 2550
Compression strength (MPa) 1470
Flexural modulus (GPa) 120
Flexural strength (MPa) 1670
A large number of different stacking configurations were tested using Abaqus. The
stacking of 8, 12, and 16 plies was investigated, and the stacking rules followed the
aerospace design principles used in industry [60]. A total of 43 laminate stackings were
investigated (Table 3). For each configuration, the FEA model enabled us to obtain the
impact energy given the maximum force matching the one obtained using Equation (1).
Table 3. Cont.
Figure Translation
Figure 4. 4. of the layers.
Translation of the layers.
2.3.Input
2.3. Inputand
andOutput
Output Definitions
Definitions
InInorder
orderto
touse
use the
the CNN
CNN models,
models,data
datainputs
inputsand
andoutputs
outputswere
weredetermined andand
determined were
were
divided in the following way (Figure
divided in the following way (Figure 5): 5):
Figure5.5.Inputs
Figure Inputsand
andoutputs
outputs of
of CNN
CNN models.
models.
Alltextual
All textualinputs,
inputs, such
such as
as fiber
fiberweaving
weavingpattern,
pattern,material type,
material and
type, state
and (prepreg
state (prepreg or or
dry), underwent encoding using one‐hot encoding. A similar approach was
dry), underwent encoding using one-hot encoding. A similar approach was employed foremployed for
non‐continuousvariables,
non-continuous variables,such
suchasasfiber
fiberorientation.
orientation. Since
Since only
only certain
certain values
values (e.g.,
(e.g., 00 and
and 90)
90) were valid orientations, one‐hot encoding was applied to represent these
were valid orientations, one-hot encoding was applied to represent these admissible admissiblevalues.
For numerical features, normalization was performed by dividing each feature by the
maximum value within our dataset. This normalization procedure constrained the value
range of each feature between 0 and 1. These preprocessing steps collectively ensured
that each data point could be represented as a set of floating-point numbers, spanning
an interval from 0 to 1. Subsequently, the data were structured according to a 2D grid
to maximize the pattern detection of the CNN, where columns correspond to distinct
layers, and rows denote the composite layer properties (Table 4). Scalar values were
incorporated as rows within this matrix, repeating the same value 28 times to occupy the
entire row uniformly. The dataset was configured as a float32 tensor, possessing dimensions
of 2725 samples × 42 properties × 28 layers. The normalization process was extended to
the outputs, ensuring the predictions aligned with the same value range.
Composite Layer
1 2 3 4 5 6 7 8
0◦ orientation 1 0 0 0 0 0 0 1
+45◦ orientation 0 1 0 0 0 0 1 0
−45◦ orientation 0 0 1 0 0 1 0 0
90◦ orientation 0 0 0 1 1 0 0 0
Unidirectional or woven 1 1 1 0 0 1 1 1
Carbon fibers 1 1 1 1 1 1 1 1
Glass fibers 0 0 0 0 0 0 0 0
Kevlar fibers 0 0 0 0 0 0 0 0
Graphite fibers 0 0 0 0 0 0 0 0
Prepreg or ‘dry’ 1 1 1 1 1 1 1 1
Core material 0 0 0 0 0 0 0 0
percentage. By default, 90% of the data were allocated for training, and the remaining 10%
were reserved for validation purposes.
Flowchart
Figure6.6.Flow
Figure chartof
ofthe
the first
first CNN
CNN architecture.
architecture.
Table
Table 5. Comparison 5. Comparison
of the of the different
different CNNs’ average CNNs’
errors. average errors.
Average ErrorAverageAverage
Error ofError
Average Error of Error
Average Average Error of Average Error of Error
Average Average Error of
of Maximum Maximum Average Error of
Force Maximum
of Maximum ofDis‐ Permanent
Permanent Inden‐ Delamination
Delamination Index In‐ Delaminated
of Delaminated Sur
Force (kN) Displacement (mm) Indentation (mm) Surface (mm2 )
(kN) placement (mm) tation (mm) dex 2 face (mm )
Standard output 0.30 0.35 0.48 0.30 62.17
Normalized outputs Standard output
0.23 0.30 0.25 0.35 0.28 0.48 0.05 0.30 76.56 62.17
Improvement betweenNormalized outputs 0.23 0.25 0.28 0.05 76.56
standard and 0.07 0.1 0.2 0.25 −14.39
normalized output Improvement be‐
TwIN_Z6_Net tween standard 0.16and 0.07 0.15 0.1 0.13 0.2 0.02 0.25 56.36 −14.39
normalized output
TwIN_Z6_Net 0.16 Network
3.2. Second Supervised 0.15 0.13 0.02 56.36
Due to the previous result, output normalization was applied to the TwIN_Z6_Net
3.2. Second Supervised Network
model. Figure 9 illustrates the progression of the loss value throughout the training of the
proposed architecture.Due toutilization
The the previousof result,
the Adamoutput normalization
optimizer was rapid
facilitates applied to the TwIN_Z6_Ne
convergence
model. Figure 9 illustrates the progression of the loss value throughout
of the model towards the minimum loss value. Notably, the early-stopping mechanism the training of th
proposed architecture. The utilization of the Adam optimizer facilitates rapid
was invoked around epoch 180 to avoid overfitting.
Materials 2023, 16, x FOR PEER REVIEW 14 of 20
Figure Training
Figure 9.9.Training lossloss
andand validation
validation loss
loss per per epoch.
epoch.
Forthe
For the evaluation
evaluation phase,phase, the error
the mean meanoferror of each
each output output
was was(Table
calculated calculated
5). A (Table 5). A
clear improvement for all outputs can be observed. The highlight of our model is
clear improvement for all outputs can be observed. The highlight of our model is reachingreaching
0.15 mm
0.15 mmprecision for for
precision all the
alllength measurements.
the length The errorThe
measurements. for each individual
error for eachsample
individual sample
within the validation dataset was assessed, and we subsequently calculated both the mean
within the validation dataset was assessed, and we subsequently calculated both the mean
and standard deviation for each output (Figure 10):
and Output
standard deviation
maximum for each 0.0116
force—mean: outputkN,(Figure
std dev:10):
0.2451
Output maximum force—mean:
Output maximum displacement—mean: −0.0132 0.0116 kN,
mm, stdstddev:
dev: 0.2451
0.3706
Output
Output maximum
permanent displacement—mean:
indentation—mean: −0.0132
−0.0170 mm, mm,
std dev: std dev: 0.3706
0.3458
Materials 2023, 16, x FOR PEER REVIEWOutput delamination surface—mean: −14.4754 mm 2, std dev: 164.2299
Output permanent indentation—mean: −0.0170 mm, std dev: 0.3458 15 of 20
Figure
Figure 10. 10. Distributionofofthe
Distribution theerror
error across
across all
allthe
themodel
modeloutputs.
outputs.
The treatment for the delamination index varied due to its binary nature, denoting
the presence or absence of delamination on a sample. A slight post‐processing step was
introduced to enhance the interpretability of the floating‐point output, enabling an easier
assessment of its proximity to 0 or 1. This involved computing the absolute error value
and applying a threshold filter, resulting in a Boolean outcome that reflects prediction
Materials 2023, 16, 7213 14 of 18
The treatment for the delamination index varied due to its binary nature, denoting
the presence or absence of delamination on a sample. A slight post-processing step was
introduced to enhance the interpretability of the floating-point output, enabling an easier
assessment of its proximity to 0 or 1. This involved computing the absolute error value and
applying a threshold filter, resulting in a Boolean outcome that reflects prediction accuracy. In
this work, it was considered that there is no delamination for an index value lower than 0.2. It
was observed that 11 samples without delamination were predicted to be delaminated, and
Materials 2023, 16, x FOR PEER REVIEW
conversely, 9 samples with actual delamination were predicted to have none (Figure 16 of 2011). In
total, the global error reached 20 out of 273 samples, yielding an error rate of 7.3%.
(a) (b)
Figure
Figure12.
12.(a)
(a)Compression
CompressionAfter
AfterImpact test
Impact set‐up
test and
set-up (b)(b)
and schematic damage
schematic thatthat
damage developed dur‐during
developed
ing Compression After Impact test.
Compression After Impact test.
4.
4. Conclusions
Conclusions
Low‐velocity/‐energy
Low-velocity/-energy impact
impact onona composite
a composite structure
structure hashas
thethe
characteristic
characteristic of caus‐
of causing
ing extensive internal damage within the layers of the material, despite
extensive internal damage within the layers of the material, despite only causing a slightly only causing a
slightly perceptible indentation on the surface. This type of damage
perceptible indentation on the surface. This type of damage results in a decrease in residualresults in a decrease
in residualpost-impact,
strength strength post‐impact,
particularly particularly
in terms in ofterms of its compressive
its compressive strength. strength.
WithinWithin
the field of
the field of aeronautics, this reduction in strength compels designers
aeronautics, this reduction in strength compels designers to consider damage tolerance to consider damage and
tolerance
restrict the and restrict the
utilization of utilization
the material’sof the material’s
full full capabilities.
capabilities. As a result,As a result, accu‐
accurately predicting
rately predicting the effects of impact damage has become
the effects of impact damage has become crucial for enhancing the remaining crucial for enhancing the strength
re‐
maining strength of composites. In this work, CNN models are proposed to predict impact
of composites. In this work, CNN models are proposed to predict impact damage in
damage in FRP composites. On one hand, data are collected from the literature, while on
FRP composites. On one hand, data are collected from the literature, while on the other
the other hand, the finite element method (FEM) is employed to simulate impact, with an
hand, the finite element method (FEM) is employed to simulate impact, with an initial
initial literature‐to‐FEM data ratio of 32%. A large amount of data information is gathered,
literature-to-FEM data ratio of 32%. A large amount of data information is gathered, and
and a data augmentation method is proposed to increase the data number from 149 to
a data augmentation method is proposed to increase the data number from 149 to 2725.
2725. The data are divided into two parts: input and output data. The first one consists of
The data arestacking
a composite divideddefinition
into twoand parts: input
of the andtest
impact output data. The
parameters. Thefirst oneone
second consists
con‐ of a
composite stacking definition and of the impact test parameters.
cerns the damage to the FRP composite, including maximum force, maximum displace‐ The second one concerns
the damage to the FRP composite, including maximum force,
ment, indentation, delamination area, and delamination index. Then, two different CNN maximum displacement,
indentation,
models delamination
are investigated andarea, and delamination
optimized. The first one is index.
basedThen, two different
on a traditional CNN models
architecture
are investigated
and and optimized.
the second consists The first
of an aggregation ofone
twoisCNNs.
basedThe on aproposed
traditional architecture
method enables us and the
second
to predictconsists of an aggregation
the impact damage to an of two
FRP CNNs.
compositeThe forproposed method enables
given stacking us to predict
configurations.
the impacttodamage
However, obtain the to best
an FRP composite
results, for givenofstacking
the aggregation two CNNs configurations.
should be consideredHowever, to
obtain
as the best
it shows betterresults, the aggregation
performance of two CNNs
than the traditional should be considered
architecture—the as it shows
first to process a ma‐better
performance
trix representing than the traditional
composite stackingarchitecture—the
and the second to first to process
process a vector acontaining
matrix representing
scalar
composite stacking
parameters and the second
(sample surface, to process
impact energy, a vector
etc.). Moreover, containing scalar parameters
normalization of the output (sample
data improves
surface, impact theenergy,
CNN model’s performance.
etc.). Moreover, The best model
normalization of reaches
the output0.15 data
mm precision
improves the
for
CNN all the lengthperformance.
model’s measurementsThe andbest
an average delaminated
model reaches 0.15 mmsurface error offor
precision 56.36
all mm ,
the 2length
and a 7% error rate is obtained on the delamination index.
measurements and an average delaminated surface error of 56.36 mm , and a 7% error rate 2
This work
is obtained on thecould facilitate theindex.
delamination process in the area of damage tolerance design by
providing rapid damage prediction
This work could facilitate the process for CFRP composite
in the area solutions. Furthermore,
of damage toleranceit has the by
design
potential to decrease the time and expenses associated with investigating
providing rapid damage prediction for CFRP composite solutions. Furthermore, it has the and formulating
novel
potentialFRPtocomposites.
decrease the In time
orderandto improve
expensesthe model, work
associated with is in progress and
investigating in order to
formulating
novel FRP composites. In order to improve the model, work is in progress in order to
increase the dataset size. Moreover, deeper analysis of the model regarding the influence of
each parameter is in progress.
Materials 2023, 16, 7213 16 of 18
Author Contributions: A.S.R.: data curation, formal analysis, validation, writing—original draft.
A.R.: coding, data curation, formal analysis, validation, writing—original draft. C.B.: writing—review.
L.M.: conceptualization, validation, writing—review and editing. All authors have read and agreed
to the published version of the manuscript.
Funding: The authors received no financial support for the research, authorship, and/or publication
of this article.
Institutional Review Board Statement: Not applicable.
Informed Consent Statement: Not applicable.
Data Availability Statement: The raw/processed data required to reproduce these findings are
available upon request.
Conflicts of Interest: The authors declare no conflict of interest.
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