Experimental and computational analysis of bending fatigue failure in chopped carbon fiber chip reinforced composites

Tang, Haibin; Zhou, Guowei; Sun, Qingping; Avinesh, Ojha; Meng, Zhaoxu; Engler-Pinto, Carlos; Su, Xuming

doi:10.1016/j.compstruct.2021.114402

Title: Experimental and computational analysis of bending fatigue failure in chopped carbon fiber chip reinforced composites

Journal Article · Tue Jul 27 00:00:00 EDT 2021 · Composite Structures

DOI:https://doi.org/10.1016/j.compstruct.2021.114402· OSTI ID:1977024

Tang, Haibin ^[1]; Zhou, Guowei ^[2]; Sun, Qingping ^[3]; Avinesh, Ojha ^[4]; Meng, Zhaoxu ^[5]; Engler-Pinto, Carlos ^[4]; Su, Xuming ^[4]

Nanjing University of Science and Technology (China); National Uninersity of Singapore (Singapore)
Shanghai Jiao Tong Univ. (China)
Nanjing University of Science and Technology (China); McMaster University, Hamilton, ON (Canada)
Ford Motor Company, Dearborn, MI (United States)
Clemson University, SC (United States)

With a better balance among good mechanical performance, high freedom of design, and low material and manufacturing cost, chopped carbon fiber chip reinforced sheet molding compound (SMC) composites show great potential in different engineering applications. Here in this paper, bending fatigue behaviors of SMC composites considering the heterogeneous fiber orientation distributions have been thoroughly investigated utilizing both experimental and computational methods. First, four-point bending fatigue tests are performed with designed SMC composites, and the local modulus is adopted as a metric to represent the local fiber orientation of two opposing sides. Interestingly, SMC composites with and without large discrepancy in local modulus of opposing sides show different fatigue behaviors. Interrupted tests are conducted to explore the bending fatigue failure mechanism, and the damage processes of valid specimens are also closely examined. We find that the fatigue failure of SMC composites under four-point bending is governed by crack propagation instead of crack initiation. Because of this, the heterogeneous local fiber orientations of both sides of the specimen influence fatigue life. The microstructure of the lower side shows a direct influence while that of the upper side also exhibiting influence which becomes more prominent for high cycle fatigue cases. Furthermore, a hybrid micro–macro computational model is proposed to efficiently study the cyclic bending behavior of SMC composites. The region of interest is reconstructed with a modified random sequential absorption algorithm to conserve all the microstructural details including the heterogeneous fiber orientation, while the rest of the regions are modeled as homogenized macro-scale continua. Combined with a framework to capture the progressive fatigue damage under cyclic bending, the bending fatigue behaviors of SMC composites are accurately captured by the hybrid computational model comparing with our experimental analysis.

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

Sponsoring Organization:: USDOE Office of Energy Efficiency and Renewable Energy (EERE); Ford Motor Company; Clemson University

Grant/Contract Number:: EE0006867

OSTI ID:: 1977024

Journal Information:: Composite Structures, Vol. 275, Issue C; ISSN 0263-8223

Publisher:: ElsevierCopyright Statement

Country of Publication:: United States

Language:: English

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36 MATERIALS SCIENCE
chopped carbon fiber chip reinforced composites
sheet molding compound
four-point bending fatigue
fiber orientation
hybrid micro–macro computational model

Title: Experimental and computational analysis of bending fatigue failure in chopped carbon fiber chip reinforced composites

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