An integrated computational materials engineering framework to analyze the failure behaviors of carbon fiber reinforced polymer composites for lightweight vehicle applications

Sun, Qingping; Zhou, Guowei; Meng, Zhaoxu; Jain, Mukesh; Su, Xuming

doi:10.1016/j.compscitech.2020.108560

Title: An integrated computational materials engineering framework to analyze the failure behaviors of carbon fiber reinforced polymer composites for lightweight vehicle applications

Journal Article · Wed Nov 18 00:00:00 EST 2020 · Composites Science and Technology

DOI:https://doi.org/10.1016/j.compscitech.2020.108560· OSTI ID:1848460

Sun, Qingping ^[1]; Zhou, Guowei ^[2];

^[3]; Jain, Mukesh ^[4]; Su, Xuming ^[5]

McMaster Univ., Hamilton, ON (Canada). Dept. of Mechanical Engineering; Nanjing Univ. of Aeronautics and Astronautics, Nanjing (China). College of Energy and Power Engineering
The Ohio State Univ., Columbus, OH (United States). College of Engineering
Clemson Univ., SC (United States). Dept. of Mechanical Engineering
McMaster Univ., Hamilton, ON (Canada). Dept. of Mechanical Engineering
Ford Motor Company, Detroit, MI (United States). Dept. of Materials Manufacturing

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 of the interphase region are determined by an analytical gradient model and molecular dynamics analysis at the nano-scale, which is then incorporated into micro-scale unidirectional (UD) representative volume element (RVE) models to characterize the failure strengths and envelopes of UD CFRP composites. Then, the results are leveraged to propose an elasto-plastic-damage constitutive law for UD composites to study the fiber tows of woven composites as well as the chips of sheet molding compound (SMC) composites. Subsequently, the failure mechanisms and failure strengths of woven and SMC composites are predicted by the meso-scale RVE models. Finally, building upon the models and results from lower scales, we show that a homogenized macro-scale model can capture the mechanical performance of a hat-section-shaped part under four-point bending. Along with the model integration, we will also demonstrate that the computational results are in good agreement with experiments conducted at different scales. The present work illustrates the potential and significance of integrated multi-scale computational modeling tools that can virtually evaluate the performance of CFRP composites and provide design guidance for CFRP composites used in structural applications.

View Accepted Manuscript (DOE)

View Accepted Manuscript (Publisher)

Cite

Export

Save

Research Organization:: Ford Motor Company, Detroit, MI (United States)

Sponsoring Organization:: USDOE Office of Energy Efficiency and Renewable Energy (EERE); China Scholarship Council (CSC); Clemson University; SC TRIMH

Grant/Contract Number:: EE0006867; P20 GM121342

OSTI ID:: 1848460

Alternate ID(s):: OSTI ID: 1777572

Journal Information:: Composites Science and Technology, Vol. 202, Issue C; ISSN 0266-3538

Publisher:: ElsevierCopyright Statement

Country of Publication:: United States

Language:: English

References (46)

Predictive multiscale modeling for Unidirectional Carbon Fiber Reinforced Polymers Gao, Jiaying; Shakoor, Modesar; Domel, Gino Composites Science and Technology, Vol. 186 https://doi.org/10.1016/j.compscitech.2019.107922	journal	January 2020
On micromechanics approach to stiffness and strength of unidirectional composites Huang, Zheng-Ming Journal of Reinforced Plastics and Composites, Vol. 38, Issue 4 https://doi.org/10.1177/0731684418811938	journal	November 2018
Multiscale surrogate-based framework for reliability analysis of unidirectional FRP composites Omairey, Sadik L.; Dunning, Peter D.; Sriramula, Srinivas Composites Part B: Engineering, Vol. 173 https://doi.org/10.1016/j.compositesb.2019.106925	journal	September 2019
Effect of heterogeneous interphase on the mechanical properties of unidirectional fiber composites studied by FFT-based method Wang, Bing; Fang, Guodong; Liu, Shuo Composite Structures, Vol. 220 https://doi.org/10.1016/j.compstruct.2019.04.049	journal	July 2019
An engineering solution for mesh size effects in the simulation of delamination using cohesive zone models Turon, A.; Dávila, C. G.; Camanho, P. P. Engineering Fracture Mechanics, Vol. 74, Issue 10 https://doi.org/10.1016/j.engfracmech.2006.08.025	journal	July 2007
Integrated computational materials engineering for advanced materials: A brief review Yi Wang, William; Li, Jinshan; Liu, Weimin Computational Materials Science, Vol. 158 https://doi.org/10.1016/j.commatsci.2018.11.001	journal	February 2019
Generation of random distribution of fibres in long-fibre reinforced composites Melro, A.; Camanho, P.; Pinho, S. Composites Science and Technology, Vol. 68, Issue 9 https://doi.org/10.1016/j.compscitech.2008.03.013	journal	July 2008
A Progressive Quadratic Failure Criterion for a Laminate Liu, K. Composites Science and Technology, Vol. 58, Issue 7 https://doi.org/10.1016/S0266-3538(96)00141-8	journal	July 1998
On the asymmetric yield surface of plastically orthotropic materials: A phenomenological study Liu, C. Acta Materialia, Vol. 45, Issue 6 https://doi.org/10.1016/S1359-6454(96)00349-7	journal	June 1997
Predicting the Macroscopic Fracture Energy of Epoxy Resins from Atomistic Molecular Simulations Meng, Zhaoxu; Bessa, Miguel A.; Xia, Wenjie Macromolecules, Vol. 49, Issue 24 https://doi.org/10.1021/acs.macromol.6b01508	journal	December 2016
Failure criteria of unidirectional carbon fiber reinforced polymer composites informed by a computational micromechanics model Sun, Qingping; Zhou, Guowei; Meng, Zhaoxu Composites Science and Technology, Vol. 172 https://doi.org/10.1016/j.compscitech.2019.01.012	journal	March 2019
Notch insensitivity in fatigue failure of chopped carbon fiber chip-reinforced composites using experimental and computational analysis Tang, Haibin; Chen, Zhangxing; Avinesh, Ojha Composite Structures, Vol. 244 https://doi.org/10.1016/j.compstruct.2020.112280	journal	July 2020
Interfacial mechanics and viscoelastic properties of patchy graphene oxide reinforced nanocomposites Li, Tianjiao; Meng, Zhaoxu; Keten, Sinan Carbon, Vol. 158 https://doi.org/10.1016/j.carbon.2019.10.039	journal	March 2020
A unified framework for the multi-scale computational homogenisation of 3D-textile composites Ullah, Z.; Zhou, X. -Y.; Kaczmarczyk, L. Composites Part B: Engineering, Vol. 167 https://doi.org/10.1016/j.compositesb.2019.03.027	journal	June 2019
Experimental and computational analysis of failure mechanisms in unidirectional carbon fiber reinforced polymer laminates under longitudinal compression loading Sun, Qingping; Guo, Haiding; Zhou, Guowei Composite Structures, Vol. 203 https://doi.org/10.1016/j.compstruct.2018.06.028	journal	November 2018
Lightweight design of carbon twill weave fabric composite body structure for electric vehicle Liu, Qiang; Lin, Yongzhou; Zong, Zhijian Composite Structures, Vol. 97 https://doi.org/10.1016/j.compstruct.2012.09.052	journal	March 2013
Finite element modeling of mode I delamination growth in laminated DCB specimens with R-curve effects Heidari-Rarani, M.; Shokrieh, M. M.; Camanho, P. P. Composites Part B: Engineering, Vol. 45, Issue 1 https://doi.org/10.1016/j.compositesb.2012.09.051	journal	February 2013
Failure mechanisms of cross-ply carbon fiber reinforced polymer laminates under longitudinal compression with experimental and computational analyses Sun, Qingping; Zhou, Guowei; Guo, Haiding Composites Part B: Engineering, Vol. 167 https://doi.org/10.1016/j.compositesb.2018.12.041	journal	June 2019
Effects of environmental degradation on near-fiber nanomechanical properties of carbon fiber epoxy composites Zhao, Wei; Singh, Raman P.; Korach, Chad S. Composites Part A: Applied Science and Manufacturing, Vol. 40, Issue 5 https://doi.org/10.1016/j.compositesa.2009.02.015	journal	May 2009
An integrated computational materials engineering-anchored closed-loop method for design of aluminum alloys for additive manufacturing Thapliyal, Saket; Komarasamy, Mageshwari; Shukla, Shivakant Materialia, Vol. 9 https://doi.org/10.1016/j.mtla.2019.100574	journal	March 2020
Micromechanical analysis of polymer composites reinforced by unidirectional fibres: Part I – Constitutive modelling Melro, A. R.; Camanho, P. P.; Andrade Pires, F. M. International Journal of Solids and Structures, Vol. 50, Issue 11-12 https://doi.org/10.1016/j.ijsolstr.2013.02.009	journal	June 2013
Failure of chopped carbon fiber Sheet Molding Compound (SMC) composites under uniaxial tensile loading: Computational prediction and experimental analysis Chen, Zhangxing; Tang, Haibin; Shao, Yimin Composites Part A: Applied Science and Manufacturing, Vol. 118 https://doi.org/10.1016/j.compositesa.2018.12.021	journal	March 2019
Yield and failure criteria for composite materials under static and dynamic loading Daniel, Isaac M. Progress in Aerospace Sciences, Vol. 81 https://doi.org/10.1016/j.paerosci.2015.11.003	journal	February 2016
A novel mesoscopic progressive damage model for 3D angle-interlock woven composites Zheng, Tao; Guo, Licheng; Huang, Jinzhao Composites Science and Technology, Vol. 185 https://doi.org/10.1016/j.compscitech.2019.107894	journal	January 2020
A new yield and failure theory for composite materials under static and dynamic loading Daniel, Isaac M.; Daniel, Sam M.; Fenner, Joel S. International Journal of Solids and Structures, Vol. 148-149 https://doi.org/10.1016/j.ijsolstr.2017.08.036	journal	September 2018
Multiscale Modeling of Composite Materials: a Roadmap Towards Virtual Testing LLorca, J.; González, C.; Molina-Aldareguía, J. M. Advanced Materials, Vol. 23, Issue 44 https://doi.org/10.1002/adma.201101683	journal	October 2011
Physically based failure models and criteria for laminated fibre-reinforced composites with emphasis on fibre kinking. Part II: FE implementation Pinho, S. T.; Iannucci, L.; Robinson, P. Composites Part A: Applied Science and Manufacturing, Vol. 37, Issue 5 https://doi.org/10.1016/j.compositesa.2005.06.008	journal	May 2006
Designing multi-layer graphene-based assemblies for enhanced toughness in nacre-inspired nanocomposites Xia, Wenjie; Song, Jake; Meng, Zhaoxu Molecular Systems Design & Engineering, Vol. 1, Issue 1 https://doi.org/10.1039/C6ME00022C	journal	January 2016
Fatigue behavior analysis and multi-scale modelling of chopped carbon fiber chip-reinforced composites under tension-tension loading condition Tang, Haibin; Zhou, Guowei; Chen, Zhangxing Composite Structures, Vol. 215 https://doi.org/10.1016/j.compstruct.2019.02.041	journal	May 2019
Effect of fiber positioning on mixed-mode fracture of interfacial debonding in composites Ashouri Vajari, Danial; Sørensen, Bent F.; Legarth, Brian Nyvang International Journal of Solids and Structures, Vol. 53 https://doi.org/10.1016/j.ijsolstr.2014.10.023	journal	January 2015
High-fidelity micro-scale modeling of the thermo-visco-plastic behavior of carbon fiber polymer matrix composites Bai, Xiaoming; Bessa, Miguel A.; Melro, António R. Composite Structures, Vol. 134 https://doi.org/10.1016/j.compstruct.2015.08.047	journal	December 2015
Prediction of in situ strengths and matrix cracking in composites under transverse tension and in-plane shear Camanho, Pedro P.; Dávila, Carlos G.; Pinho, Silvestre T. Composites Part A: Applied Science and Manufacturing, Vol. 37, Issue 2 https://doi.org/10.1016/j.compositesa.2005.04.023	journal	February 2006
Process Integration and Optimization of ICME Carbon Fiber Composites for Vehicle Lightweighting: A Preliminary Development Xu, Hongyi; Li, Yang; Zeng, Danielle SAE International Journal of Materials and Manufacturing, Vol. 10, Issue 3 https://doi.org/10.4271/2017-01-0229	journal	January 2017
Stiffness Enhancement in Nacre-Inspired Nanocomposites due to Nanoconfinement Shao, Chen; Keten, Sinan Scientific Reports, Vol. 5, Issue 1 https://doi.org/10.1038/srep16452	journal	November 2015
Uncertainty quantification of mechanical properties for three-dimensional orthogonal woven composites. Part II: Multiscale simulation Tao, Wei; Zhu, Ping; Xu, Can Composite Structures, Vol. 235 https://doi.org/10.1016/j.compstruct.2019.111764	journal	March 2020
Nano-analysis on the structure and chemical composition of the interphase region in carbon fiber composite Wu, Qing; Li, Min; Gu, Yizhuo Composites Part A: Applied Science and Manufacturing, Vol. 56 https://doi.org/10.1016/j.compositesa.2013.10.003	journal	January 2014
Load carrying characteristics of short fiber composites containing a heterogeneous interphase region Kiritsi, C. C.; Anifantis, N. K. Computational Materials Science, Vol. 20, Issue 1 https://doi.org/10.1016/S0927-0256(00)00129-4	journal	January 2001
Correlation between failure and local material property in chopped carbon fiber chip‐reinforced sheet molding compound composites under tensile load Tang, Haibin; Chen, Zhangxing; Zhou, Guowei Polymer Composites, Vol. 40, Issue S2 https://doi.org/10.1002/pc.24767	journal	February 2018
Prediction of Interfacial Debonding in Fiber‐Reinforced Composite Laminates Zhou, Yi; Huang, Zheng‐Ming; Liu, Ling Polymer Composites, Vol. 40, Issue 5 https://doi.org/10.1002/pc.24943	journal	August 2018
A Multiscale Model for the Quasi-Static Thermo-Plastic Behavior of Highly Cross-Linked Glassy Polymers Vu-Bac, N.; Bessa, M. A.; Rabczuk, Timon Macromolecules, Vol. 48, Issue 18 https://doi.org/10.1021/acs.macromol.5b01236	journal	September 2015
Crushing behaviors of unidirectional carbon fiber reinforced plastic composites under dynamic bending and axial crushing loading Zhou, Guowei; Sun, Qingping; Fenner, Joel International Journal of Impact Engineering, Vol. 140 https://doi.org/10.1016/j.ijimpeng.2020.103539	journal	June 2020
A comparative study of twill weave reinforced composites under tension–tension fatigue loading: Experiments and meso-modelling Xu, J.; Lomov, S. V.; Verpoest, I. Composite Structures, Vol. 135 https://doi.org/10.1016/j.compstruct.2015.09.005	journal	January 2016
Measurement of small angle fiber misalignments in continuous fiber composites Yurgartis, S. W. Composites Science and Technology, Vol. 30, Issue 4 https://doi.org/10.1016/0266-3538(87)90016-9	journal	January 1987
Multi-scale computational analysis of unidirectional carbon fiber reinforced polymer composites under various loading conditions Sun, Qingping; Meng, Zhaoxu; Zhou, Guowei Composite Structures, Vol. 196 https://doi.org/10.1016/j.compstruct.2018.05.025	journal	July 2018
Life-Cycle Energy and Greenhouse Gas Emission Benefits of Lightweighting in Automobiles: Review and Harmonization Kim, Hyung Chul; Wallington, Timothy J. Environmental Science & Technology, Vol. 47, Issue 12 https://doi.org/10.1021/es3042115	journal	May 2013
A Progressive Damage Model for Laminated Composites Containing Stress Concentrations Chang, Fu-Kuo; Chang, Kuo-Yen Journal of Composite Materials, Vol. 21, Issue 9 https://doi.org/10.1177/002199838702100904	journal	September 1987

Similar Records

Process Integration and Optimization of ICME Carbon Fiber Composites for Vehicle Lightweighting: A Preliminary Development

Journal Article · Mon Jan 02 00:00:00 EST 2017 · SAE International Journal of Materials and Manufacturing · OSTI ID:1848460

Xu, Hongyi; Li, Yang; Zeng, Danielle

Multiscale Modeling of Carbon Fiber Reinforced Polymer (CFRP) for Integrated Computational Materials Engineering Process

Conference · Mon Oct 23 00:00:00 EDT 2017 · OSTI ID:1848460

Gao, Jiaying; Liang, Biao; Zhang, Weizhao; +9 more

Multi-scale computational analysis of unidirectional carbon fiber reinforced polymer composites under various loading conditions

Journal Article · Thu May 03 00:00:00 EDT 2018 · Composite Structures · OSTI ID:1848460

Sun, Qingping; Meng, Zhaoxu; Zhou, Guowei; +5 more

Related Subjects

36 MATERIALS SCIENCE
Materials science
Integrated computational materials engineering (ICME)
Multi-scale modeling
Carbon fiber reinforced polymer (CFRP) composites
Lightweight applications

Title: An integrated computational materials engineering framework to analyze the failure behaviors of carbon fiber reinforced polymer composites for lightweight vehicle applications

Citation Formats

References (46)

Similar Records

Related Subjects