Notch insensitivity in fatigue failure of chopped carbon fiber chip-reinforced composites using experimental and computational analysis

Published on Jul 15, 2020in Composite Structures5.138
· DOI :10.1016/J.COMPSTRUCT.2020.112280
Haibin Tang5
Estimated H-index: 5
(NUAA: Nanjing University of Aeronautics and Astronautics),
Zhangxing Chen5
Estimated H-index: 5
(Ford Motor Company)
+ 5 AuthorsXuming Su18
Estimated H-index: 18
(Ford Motor Company)
Source
Abstract
Abstract This study focuses on the notch effect on the fatigue failure of chopped carbon fiber chip-reinforced sheet molding compound (SMC) composites by using both experimental and numerical methods. The S-N diagrams of notched specimens are first obtained experimentally, which exhibit large scatter and are shown to depend on the spatial distribution of local fiber orientations. After considering the effect of this spatial distribution by adopting a new fatigue damage parameter to normalize the results, we achieve a much better correlation in the normalized S-N diagram for all the notched specimens with different hole diameters. Next, compared with the fatigue results of smooth specimens without notches, we find that SMC composites under tension-tension fatigue loading exhibit notch-insensitivity, which renders this type of composites a better candidate in joints or similar applications. Meanwhile, the fatigue failure mechanisms of notched SMC composites are explored through a microstructure characterization procedure. On this basis, a computational micromechanics model considering the notch effect and an improved multi-scale progressive damage fatigue law, calibrated by coupon-level fatigue tests of smooth SMC composites under different loading conditions, are employed to predict the fatigue behavior of notched SMC composites. We show that detailed failure processes and fatigue life of notched SMC composites can be efficiently and adequately predicted by this computational framework.
📖 Papers frequently viewed together
13 Citations
2015
11 Citations
References40
Newest
#1Haibin Tang (NUAA: Nanjing University of Aeronautics and Astronautics)H-Index: 5
#2Zhangxing Chen (Chongqing University)H-Index: 5
Last. Xuming Su (Ford Motor Company)H-Index: 18
view all 11 authors...
Abstract The material behavior of chopped carbon fiber chip-reinforced Sheet Molding Compound (SMC) composite is investigated under both quasi-static and cyclic fatigue loading conditions in the present study. Quasi-static tensile and compressive strength data is collected, followed by a series of fatigue tests under three different cyclic loading conditions, i.e., Tension-Tension (T-T), Compression-Compression (C-C), and Tension-Compression (T-C). The experimental results show a considerable am...
9 CitationsSource
#1Klas Solberg (NTNU: Norwegian University of Science and Technology)H-Index: 7
#2Filippo Berto (NTNU: Norwegian University of Science and Technology)H-Index: 68
Abstract Powder bed fusion based additively manufactured components are known to have poor surface quality, especially when building downward facing surfaces. These surfaces can contain defects, from which fatigue cracks can be initiated. In this work the notched fatigue behaviour of Inconel 718 specimens produced by selective laser melting is investigated. The main focus is set on the interaction between notch geometries and local defects due to the amount of overhang in the notch region. Four ...
30 CitationsSource
#1Haibin Tang (NUAA: Nanjing University of Aeronautics and Astronautics)H-Index: 5
#2Guowei Zhou (OSU: Ohio State University)H-Index: 12
Last. Xuming Su (Ford Motor Company)H-Index: 18
view all 12 authors...
Abstract In present study, the fatigue damage behavior of chopped carbon fiber chip-reinforced composite has been experimentally and numerically investigated. A large scatter is exhibited in the S-N diagram due to the random distribution of carbon fiber chips, and therefore a new analysis procedure is proposed to link the local microstructure to the fatigue behavior of the bulk material. Interrupted fatigue tests are also performed so that microstructure characterization can be conducted on the ...
11 CitationsSource
#1Zhangxing Chen (Chongqing University)H-Index: 5
#2Haibin Tang (NUAA: Nanjing University of Aeronautics and Astronautics)H-Index: 5
Last. Xuming Su (Ford Motor Company)H-Index: 18
view all 9 authors...
Abstract This paper presents a computational framework to predict the tensile failure of chopped carbon fiber SMC composites based on the Representative Volume Element (RVE) model. In the framework, a conforming mesh-based reconstruction algorithm is developed to generate mesostructure RVE models of SMC based on the statistical characteristics. Moreover, constitutive models are proposed for the three phases in SMC composites: fiber chip, matrix, and interface. The model predictions are validated...
17 CitationsSource
#1Bowen Liu (HIT: Harbin Institute of Technology)H-Index: 2
#2Xiangqiao Yan (HIT: Harbin Institute of Technology)H-Index: 2
Abstract Based on the theory of critical distances (TCD), a new multiaxial notch fatigue life prediction method is proposed in this paper. Firstly, inspired by the means for determining the critical distance of fatigue limit shown in Kitagawa and Takahashi’s diagram, a new measure is proposed to extend the means to the finite life interval. Then, by combining this new measure and the Sih et al. mixed mode fracture criterion, the relationship between axial and torsional notch fatigue lives can be...
10 CitationsSource
#1Yi Li (NU: Northwestern University)H-Index: 2
#2Zhangxing Chen (Chongqing University)H-Index: 5
Last. Hongyi Xu (Ford Motor Company)H-Index: 13
view all 6 authors...
Abstract To establish an integrated Processing-Microstructure-Property workflow for the prediction of material behaviors, this paper presents a new stochastic pseudo-3D microstructure reconstruction method for Sheet Molding Compounds (SMC) chopped fiber composites. The proposed method captures the bi-level microstructural features of SMC composites. At the higher level, a Voronoi diagram-based algorithm is developed to reconstruct the unique substructure features of SMC fiber tows. The geometry ...
8 CitationsSource
#1Qingping Sun (NUAA: Nanjing University of Aeronautics and Astronautics)H-Index: 8
#2Zhaoxu Meng (NU: Northwestern University)H-Index: 13
Last. Xuming Su (Ford Motor Company)H-Index: 18
view all 8 authors...
Abstract A multi-scale computational analysis based on representative volume element (RVE) modeling and molecular dynamics (MD) simulations is developed to investigate the microscopic failure mechanisms of unidirectional (UD) carbon fiber reinforced polymer (CFRP) composites. The average properties of the 200-nm thickness interphase region between fiber and matrix are characterized through MD simulations and an analytical gradient model. The results demonstrate that the interphase region has hig...
40 CitationsSource
#1Zhangxing Chen (Chongqing University)H-Index: 5
#2Tianyu Huang (NU: Northwestern University)H-Index: 4
Last. Xuming Su (Ford Motor Company)H-Index: 18
view all 9 authors...
Abstract Predicting the mechanical behavior of the chopped carbon fiber Sheet Molding Compound (SMC) due to spatial variations in local material properties is critical for the structural performance analysis but is computationally challenging. Such spatial variations are induced by the material flow in the compression molding process. In this work, a new multiscale SMC modeling framework and the associated computational techniques are developed to provide accurate and efficient predictions of SM...
24 CitationsSource
#1Haibin Tang (NUAA: Nanjing University of Aeronautics and Astronautics)H-Index: 5
#2Zhangxing ChenH-Index: 7
Last. Xuming SuH-Index: 18
view all 9 authors...
12 CitationsSource
#1Shan-Shan YaoH-Index: 3
#2Fan-Long JinH-Index: 30
Last. Soo-Jin Park (IIT: Inha University)H-Index: 112
view all 5 authors...
Abstract Carbon fibers (CFs) have high specific tensile strength, high modulus, and outstanding wear resistance, and are widely used for the reinforcement of advanced composite materials. CF-reinforced thermoplastic composites have received much attention because of their easy processability and recycling convenience compared with thermosetting composites. Surface treatment of CFs is generally employed to increase the surface functional groups and interfacial adhesion between the CFs and the sur...
185 CitationsSource
Cited By5
Newest
#1Qingping Sun (Nanjing Tech University)
#1Qingping Sun (Nanjing Tech University)H-Index: 8
Last. Weijian Han (Nanjing Tech University)H-Index: 1
view all 7 authors...
Abstract In this work, multi-scale finite element analyses based on three-dimensional (3D) hybrid macro/micro-scale computational models subjected to various loading conditions are carried out to examine the in-situ effect imposed by the neighboring plies on the failure initiation and propagation of cross-ply laminates. A detailed comparative study on crack suppression mechanisms due to the effect of embedded laminar thickness and adjacent ply orientation is presented. Furthermore, we compare th...
1 CitationsSource
#1Qingping Sun (NUAA: Nanjing University of Aeronautics and Astronautics)H-Index: 8
#2Guowei Zhou (OSU: Ohio State University)H-Index: 12
Last. Xuming Su (Ford Motor Company)H-Index: 18
view all 5 authors...
Abstract A bottom-up multi-scale modeling approach is used to develop an Integrated Computational Materials Engineering (ICME) framework for carbon fiber reinforced polymer (CFRP) composites, which has the potential to reduce development to deployment lead time for structural applications in lightweight vehicles. In this work, we develop and integrate computational models comprising of four size scales to fully describe and characterize three types of CFRP composites. In detail, the properties o...
4 CitationsSource
#1Haibin Tang (NUS: National University of Singapore)H-Index: 5
#2Hui Chen (NUS: National University of Singapore)H-Index: 13
Last. Wentao Yan (NUS: National University of Singapore)H-Index: 17
view all 5 authors...
Abstract A fundamental understanding of structure-property relationship of carbon fiber reinforced polymer (CFRP) composites fabricated by selective laser sintering (SLS) is essential to provide guidance to improve the mechanical properties in this promising additive manufacturing process. In the present study, we propose a new computational framework to evaluate the mechanical behavior of SLSed CFRP based on the representative volume element (RVE) model. Firstly, a new voxel-based fiber packing...
3 CitationsSource
#1Haibin Tang (NUS: National University of Singapore)H-Index: 5
#2Zhangxing ChenH-Index: 7
Last. Xuming Su (Ford Motor Company)H-Index: 18
view all 9 authors...
Abstract Chopped carbon fiber sheet molding compound has a great potential in lightweight automotive, marine, and aerospace applications. One of the most challenging tasks is to predict the failure strength of the material due to its anisotropy and heterogeneity, as well as complex stress states in real-world working conditions. In this paper, a novel constitutive model of carbon fiber chip is proposed to capture the pre- and post-failure behaviors under different loading modes. On this basis, w...
3 CitationsSource
Source