3d Fibre Reinforced Polymer Composites

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Manufacturing Processes For Advanced Composites

Tensile failure of laminates containing an embedded wrinkle; numerical and experimental study Part A Applied science and manufacturing

Out-of-plane fiber waviness, also referred to as wrinkling, is considered one of the most significant effects that occur in composite materials. It significantly affects mechanical properties, such as stiffness, strength and fatigue and; therefore, dramatically reduces the load-carrying capacity of the material. Fiber waviness is inherent to various manufacturing processes of fiber-reinforced composite parts. They cannot be completely avoided and thus have to be tolerated and considered as an integral part of the structure. Because of this influenceable but in many cases unavoidable nature of fiber waviness, it might be more appropriate to consider fiber waviness as effects or features rather than defects. Hence, it is important to understand the impact of different process parameters on the formation of fiber waviness in order to reduce or, in the best case, completely avoid them as early as possible in the product and process development phases. Mostly depending on the chosen geometry of the part and the specific manufacturing process used, different types of fiber waviness result. In this study, various types of waviness are investigated and a classification scheme is developed for categorization purposes. Numerous mechanisms of wrinkling were analyzed, leading to several recommendations to prevent wrinkle formation, not only during composite processing, but also at an earlier design stage, where generally several influence factors are defined.

https://www.mdpi.com/2504-477X/4/3/130/pdf

Mechanisms of origin and classification of out-of-plane fiber waviness in composite materials — A review

In recent years, most boat fabrication companies use 100% synthetic fiber-reinforced composite materials, due to their high performance of mechanical properties. In the new trend of research on the fabrication of boat structure using natural fiber hybrid with kevlar/fiberglass-reinforced composite, the result of tensile, bending, and impact strength showed that glass fiber-reinforced polyester composite gave high strength with increasing glass fiber contents. At some point, realizing the cost of synthetic fiber is getting higher, researchers today have started to use natural fibers that are seen as a more cost-effective option. Natural fibers, however, have some disadvantages, such as high moisture absorption, due to repelling nature; low wettability; low thermal stability; and quality variation, which lead to the degradation of composite properties. In recent times, hybridization is recommended by most researchers as a solution to natural fiber’s weaknesses and to reduce the use of synthetic fibers that are not environmentally friendly. In addition, hybrid composite has its own special advantages, i.e., balanced strength and stiffness, reduced weight and cost, improved fatigue resistance and fracture toughness, and improved impact resistance. The synthetic–nature fiber hybrid composites are used in a variety of applications as a modern material that has attracted most manufacturing industries’ attention to shift to using the hybrid composite. Some of the previous studies stated that delamination and manufacturing had influenced the performance of the hybrid composites. In order to expand the use of natural fiber as a successful reinforcement in hybrid composite, the factor that affects the manufacturing defects needs to be investigated. In this review paper, a compilation of the reviews on the delamination and a few common manufacturing defect types illustrating the overview of the impact on the mechanical properties encountered by most of the composite manufacturing industries are presented.

https://www.mdpi.com/2073-4360/13/8/1323/pdf

Delamination and Manufacturing Defects in Natural Fiber-Reinforced Hybrid Composite: A Review.

The limited capability to predict material failure in composite materials and specifically in wavy composite layers has led to high margins of safety for the design of composite structures. Thus, the full lightweight potential of this class of materials is left unused. To understand the complex failure behavior of composite materials containing out-of-plane fiber waviness under compressive and tensile loading, a non-linear 2D material model was implemented in ABAQUS and validated with extensive experimental test data from compression and tensile tests. Each test was recorded by a stereo camera system for digital image correlation to resolve damage initiation and propagation in detail. This study has shown excellent agreement of numerical simulations with experimental data. In a virtual testing approach various parameters, i.e. amplitude, wavelength and laminate thickness, have been studied. It was found that the failure mode changed from delamination to kink shear band formation with increasing laminate thickness. The wavelength has shown minor influences compared to amplitude and laminate thickness.

/pdf/numerical-and-experimental-investigation-of-out-of-plane-2p5868736s.pdf

Numerical and experimental investigation of out-of-plane fiber waviness on the mechanical properties of composite materials

o accurately simulate the foam core in composite parts on a macroscopic scale the morphology, the characterisation, and the nonlinear behaviour of thefoam must be understood properly. Accounting for the heterogeneity and the mechanical properties of the foam core affects the dimensioning of the final part.In the present study the microstructure of the foam samples were characterized using scanning electron microscopy. To determine the bulk material behavior and the strength limitations of the nonlinear foam, shear and compressions tests are performed. All numerical calculations were carried out on the macroscopic level.A basic challenge in the finite element modelling of hyperelastic materials by means of test data is the identification of material model coefficients which are appropriate to describe the behaviour of the considered foam.

Roland M. Hinterhölzl

Papers

Mechanisms of origin and classification of out-of-plane fiber waviness in composite materials — A review

Numerical and experimental investigation of out-of-plane fiber waviness on the mechanical properties of composite materials

Analysis of the Macroscopic Behaviour of PMI Foam