Monitoring structural scale composite specimens in a post‐buckling regime: The integrated finite element stereo digital image correlation approach with geometrically non‐linear regularization

Even though the simulations used to describe the failure of laminates are becoming more and more predictive, complex testing under multiaxial loadings is still required to validate the design of structural parts in a wide range of industrial domains. It is thus essential to assess the actual boundary conditions to allow for an objective comparison between testing and calculations, in particular since the structural tests are complex and often leads to buckling. Therefore, accurate estimation of force and moment fluxes applied to the specimen is critical. In this context, stereo digital image correlation (SDIC) has proven to be an important measurement tool and provides very well‐resolved surface displacement fields, but the exploitation of such measurements to calculate fluxes remains problematic when testing composites. The first objective of this study is both to reduce the uncertainty associated with fluxes determination on a complex test and to simplify the extraction process with respect to existing procedures. The second objective is to make this methodology robust to geometrically non‐linear deformations. In this paper, we propose a new methodology that extracts minimal boundary conditions in the form of 3D mechanically admissible displacements fields. The approach developed uses a finite element SDIC (FE‐SDIC) method regularized by means of mechanical behaviour admissibility equations. Results show that the new methodology outputs much more accurate fluxes than classical data generated from multiple differentiations of the displacement fields. Excellent noise robustness is obtained and quantified. Numerical predictions have been satisfactorily compared with experimental data from one structural‐scale composite specimen under complex testing.