Characterisation of the draping behaviour of unidirectional non-crimp fabrics (UD-NCF)

Thin composites shell structures manufactured from stitched unidirectional non-crimp fabrics (UD-NCF) in a liquid composite moulding process provides high lightweight design capabilities. However, draping behaviour of UD-NCF has been investigated only sparsely, in contrast to research on woven fabrics or biaxial non-crimp fabrics. Hence, this contribution focuses on fundamental investigations of the draping behaviour of UD-NCF. Within this investigation picture frame tests and uniaxial bias extension tests are performed to examine the in-plane shear behaviour of UD-NCF. Furthermore, a new method is presented to examine ambivalent tensile behaviour of UD-NCF transverse to the carbon fibre roving orientation. In particular, the influence of thin glass fibres on transverse tensile behaviour of UF-NCFs is investigated using a new clamping mechanism in tensile testing. Finally, hemisphere tests are performed to observe the forming behaviour of UD-NCF in a realistic forming process and to evaluate the proposed material characterisation methods regarding its suitability for UD-NCFs.     

Modelling the forming mechanics of engineering fabrics using a mutually constrained pantographic beam and membrane mesh

A method of combining 1-d and 2-d structural finite elements to capture the fundamental mechanical properties of engineering fabrics subject to finite strains is introduced. A mutually constrained pantographic beam & membrane mesh is presented and simple homogenisation theory is developed to relate the macro-scale properties of the mesh to the properties of the elements within the mesh. The theory shows that each of the macro-scale properties of the mesh can be independently controlled. An investigation into the performance of the technique is conducted using tensile, cantilever bending and uniaxial bias extension shear simulations. The simulations are first used to verify the accuracy of the homogenisation theory and then used to demonstrate the ability of the modelling approach in accurately predicting the shear force, shear kinematics and out-of-plane wrinkling behaviour of engineering fabrics.     

Establishing a new Forming Limit Curve for a flax fibre reinforced polypropylene composite through stretch forming experiments

In developing an understanding of the failure in natural fibre reinforced polymer composites, the failure limits of this class of the material system are required. It is found that the conventional Forming Limit Curve is not suitable to predict the failure initiated in the natural fibre composite as principal strains cannot differentiate the strain on the flax fibres and the polypropylene matrix. This study proposes a new Forming Limit Curve for the composite which expresses limiting fibre strain as a function of forming mode depicted by the ratio of minor strain to major strain. The new Forming Limit Curve, along with the Maximum Strain failure criterion have been successfully implemented in FEA simulations, and numerical simulations suggest that the former is more accurate. The current work provides an innovative method to predict the onset of failure in natural fibre composites, which can be applied in composite forming and structural design.     

Analysis of the thermomechanical shear behaviour of woven-reinforced thermoplastic-matrix composites during forming

Shear behaviour of a glass fibre/polypropylene composite is characterized over a wide range of strain rates and forming temperatures using the bias extension test. A temperature- and rate-dependent material model is here introduced to describe the observed behaviour. The model is based on a continuous approach and formulated considering a stress objective derivative based on the warp and weft yarns rotation. The effects of temperature and strain rate on the shear behaviour are analysed via bias extension test simulations. Temperature change in the sheet during forming was measured. This data is used to model cooling during forming. Isothermal and transient forming simulations were performed in order to show the effects of temperature and forming speed on the obtained shear angle distribution. It was found that at low forming speeds the assumption of isothermal forming is not valid anymore since the cooling of the sheet affects the shear behaviour.     

Experimentally based strategy for damage analysis of textile-reinforced composites under static loading

For a reliable design of components made of textile composites, a deep knowledge of their failure behaviour and of realistic damage models is necessary. Such models require the onset of damage and the evolution of different damage phenomena to be determined experimentally. In this context, an experimental damage analysis strategy is proposed here that combines crack density measurements, acoustic emission analysis and optical microscopy with the recording of stiffness degradation by ultrasonic wave speed measurements. The correlation between the results of quasi-static tests is discussed for two selected examples of textile composites: multi-layered flat bed weft-knitted glass fibre–epoxy composites and woven glass fibre–polypropylene composites made of hybrid fabrics.     

Multiscale modeling of unsaturated flow in dual-scale fiber preforms of liquid composite molding III: reactive flows

The woven, stitched or braided fabrics used in liquid composite molding (LCM) display partial saturation behind moving flow-front in an LCM mold which is caused by delayed impregnation of fiber tows. In this part 3 of the present series of three papers, a novel multiscale approach proposed in parts 1 and 2 [1] and [2] is adapted for modeling the unsaturated flow observed in the dual-scale fabrics of LCM under non-isothermal, reactive conditions. The volume-averaged species or resin cure equation, in conjunction with volume-averaged mass, momentum and energy (temperature) equations, is employed to model the reactive resin flow in the inter-tow (gap) and intra-tow (tow) regions with coupling expressed through several sink and source terms in the governing equations. A coarse global-mesh is used to solve the global (gap) flow over the entire domain, and a fine local mesh in form of the unit-cell of periodic fabrics is employed to solve the local (tow) flows. The multiscale algorithm based on the hierarchical computational grids is then extended to solve the dual-scale flow under reactive conditions. The simulation is compared with a two-color experiment and a previously published two-layer model. Significant differences between the temperatures and cures of the gap and tow regions of the dual-scale porous medium are observed. The ratio of pore volumes in the tow and gap regions, the effective thermal conductivity in the tows, and the reaction rate are identified as the important parameters for temperature and cure distributions in the gap and tow regions.     

An original approach for mechanical modelling of short-fibre reinforced composites with complex distributions of fibre orientation

In this paper, an original and effective model of behaviour for short-fibre reinforced composites is presented. In particular, complex fibre distributions of orientation can be dealt with in a very easy way, without orientation averaging or additional homogenisation steps. The matrix material has elastoplastic damage behaviour with non-isochoric plastic flow. Ductile damage can be fully anisotropic depending on the reinforcement characteristics. The model is validated for the case of a polypropylene reinforced with short flax fibres. In addition, simulations are performed to investigate the influence of key parameters like fibre length and interfacial shear strength, as well as the impact of progressive debonding at the fibre tips.     

Implementation of a constitutive micromechanical model for damage analysis in glass mat reinforced composite structures

A micromechanical model based on a probabilistic approach is implemented in the finite element code CASTEM 2000 to develop numerical simulations that efficiently predict the overall damaged behaviour of random oriented fibre composites. The proposed damage constitutive model is based upon the generalised Mori and Tanaka scheme and Eshelby's equivalence theory. Damage mechanisms occurring at each composite constituent (fibres, matrix and interface) are associated to Weibull probabilistic functions to model their onset and progressive growth at the microscopic scale level. It is obvious that the damaged behaviour of the composite material depends widely on the microscopic material parameters (fibre length, fibre volume fraction, fibre orientation, …). On one hand, the micromechanical model uses homogenisation techniques which enabled us to link these microscopic parameters to the material behaviour and to evaluate explicitly their influences. On the other hand, the implementation of the derived behaviour law into a finite element code enabled us to reflect on the effect of these microscopic parameters on the overall response of a simple composite structure presenting heterogeneous stress fields. In fact, the damage evolution in each constituent (local scale) and the related stiffness reduction are estimated at any material point (integration point) or node of the considered structure subject to a specific loading. Numerical simulations of a composite plate with a hole under in-plane tension were performed to validate the implementation of the behaviour law. Numerical results have been compared to experimental curves and damage evolutions monitored by acoustic emission techniques. Simulations agree well with experimental results in terms of damage onset and growth.     

Thermoplastic composite from innovative flat knitted 3D multi-layer spacer fabric using hybrid yarn and the study of 2D mechanical properties

Due to their improved mechanical properties, 3D multi-layer spacer fabrics could be used for lightweight applications such as textile-based sandwich preforms. Modern flat knitting machines using high performance yarns are able to knit complex 3D multi-layer spacer fabrics consisting of individual surface and connecting layers. This paper reports on the development of 3D flat knitted spacer fabric for 3D thermoplastic composites using hybrid yarns made of glass (GF) and polypropylene (PP) filaments. Moreover, mechanical properties of reinforcement yarns, 2D knit fabrics and 2D composites manufactured using various integration methods of reinforcement yarns were also studied. The integration of reinforcement yarns as biaxial inlays (warp and weft yarns) is found to be the best solution for knitting, whereas the tuck stitches show optimal results.     

Mechanical properties of hybrid composites using finite element method based micromechanics

A micromechanical analysis of the representative volume element of a unidirectional hybrid composite is performed using finite element method. The fibers are assumed to be circular and packed in a hexagonal array. The effects of volume fractions of the two different fibers used and also their relative locations within the unit cell are studied. Analytical results are obtained for all the elastic constants. Modified Halpin–Tsai equations are proposed for predicting the transverse and shear moduli of hybrid composites. Variability in mechanical properties due to different locations of the two fibers for the same volume fractions was studied. It is found that the variability in elastic constants and longitudinal strength properties was negligible. However, there was significant variability in the transverse strength properties. The results for hybrid composites are compared with single fiber composites.     

High performance thermoplastic composite from flat knitted multi-layer textile preform using hybrid yarn

Modern flat knitting machines using high performance yarns are able to knit fabrics including the reinforcement yarns arranged differently into knit structures. Due to their improved mechanical properties, composites made from multi-layer knit fabrics show great potential in lightweight applications. This paper reports on the development of flat knitted multi-layer textile preforms for high performance thermoplastic composites using hybrid yarns made of glass (GF) and polypropylene (PP) filaments. Such textile preforms with different reinforcements were used to consolidate into 2D thermoplastic composites. Moreover, the mechanical properties of these composites were studied. The mechanical properties of 2D composites were found to be greatly affected by different arrangements of reinforcement yarns. The integration of reinforcement yarns as biaxial inlays (warp and weft yarns) is found to be the best solution for knitting, whereas tuck stitch shaped and unidirectional arranged reinforcements offer also promising application possibilities.     

Evaluation of directional mesh bias in concrete fracture simulations using continuum damage models

In the present comparative study, we investigate the influence of directional mesh bias on the results of failure simulations performed with isotropic and anisotropic damage models. Several fracture tests leading to curved crack trajectories are simulated on different meshes. The isotropic damage model with a realistic biaxial strength envelope for concrete is highly sensitive to the mesh orientation, even for fine meshes. The sensitivity is reduced if the definition of the damage-driving variable (equivalent strain) is based on the modified von Mises criterion, but the corresponding biaxial strength envelope is not realistic for concrete. The anisotropic damage models used in this study capture reasonably well arbitrary crack trajectories even if the biaxial strength envelope remains close to typical experimental data. Their superior performance can be at least partially attributed to their ability to capture dilatancy under shear, which is revealed by a comparative analysis of the behavior of individual models under shear with restricted or free volume expansion.     

Mechanical behavior of Kevlar/basalt reinforced polypropylene composites

In this study, mechanical behavior of thermoplastic composites reinforced with two-dimensional plain woven homogeneous and hybrid fabrics of Kevlar/basalt yarns was studied. Five types (two homogeneous and three hybrids) of composite laminates were manufactured using compression molding technique with polypropylene (PP) resin. Static tensile and in-plane compression tests were carried out to evaluate the mechanical properties of the laminates. The tension and in-plane compression tests had shown that the composites with the combination of Kevlar and basalt yarns present better tensile and in-plane compressive behavior as compared to their base composites. Improvement in the properties such as elastic modulus, strength and failure strain in both tension and in-plane compression was observed due to the hybridization. Numerical simulations were performed in ABAQUS/Standard by implementing a user-defined material subroutine (VUMAT) based on Chang-Chang criteria. Good agreement between the experimental and numerical simulations was achieved in terms of damage patterns.     

Characterising the shear–tension coupling and wrinkling behaviour of woven engineering fabrics

Modelling the forming process for engineering fabrics and textile composites using a mechanical approach, such as the finite element method, requires characterisation of the material’s behaviour under large shear deformation. For woven engineering fabrics, a coupling between in-plane tension and both shear compliance and the onset of wrinkling is to be expected. This paper focuses on a novel testing technique, the biaxial bias extension test, as a means to investigate this shear–tension coupling and fabric wrinkling. Novel methods of determining the wrinkling behaviour are demonstrated. The main difficulty with the technique lies in extracting the material contribution to the recorded signal. To do this, an experimental method is proposed and demonstrated using a plain weave glass fabric. Biaxial bias extension test results are compared against picture frame and uniaxial bias extension results.     

Meso-modelling of Non-Crimp Fabric composites for coupled drape and failure analysis

To date macro-analysis methods have been invariably used to analyse textile composite structures for forming and mechanical performance. Techniques such as geometric ‘mapping’ for the draping of textile fabrics and classical laminate analysis combined with simplified failure criteria to determine mechanical performance have formed the basis of most of these methods. The limited accuracy of the physical laws applied is appropriate to macro-analysis methods in which the fibre-matrix composite is treated as homogeneous medium. Today, however, modern high performance computers are opening new possibilities for composites analysis in which far greater detail of the composite constituent materials may be made. This paper presents Finite Elements techniques for the draping simulation of textile composites, specifically biaxial Non Crimp Fabrics, in which the complex deformation mechanisms of the dry tows and stitching may be properly modelled at the individual tow and stitch meso-level. The resulting ‘deformed’ Finite Element model is then used to provide a basis for accurate simulation of the impregnated composite structure. The modelling techniques for both draping and structural analysis are present, together with validation results for the study of a relatively large-scale hemisphere composite part.     

Predictive modelling for optimization of textile composite forming

Wrinkling often occurs during textile composite forming and is a major problem for manufacturers. The prediction of this defect is, therefore, of major importance for the design and optimization of textile composite structures. Numerical simulations of forming for textile composites over a hemisphere have been conducted using a rate/temperature-dependent hybrid FE model. The hybrid FE model incorporates a fully predictive multi-scale energy model which determines the shear resistance of the textile composite sheet. The effects of varying the normal force distribution across the edges of the blank and blank size, together with the effect of changes in forming temperature on the final fibre pattern and wrinkling behaviour, are investigated. Predictions are evaluated against press-formed components. The results from the simulation and the experiments have good correlation and show that wrinkling can be minimized by optimizing the force distribution around the edge of the manufacturing tool and by careful choice of forming temperature.     

On the effect of stacked fabric layers on the stiffness of a woven composite

Most micromechanical models for stiffness prediction of woven composites assume independence of the Q-matrix on the number of fabric layers in the composite. For example, the moduli of single and 10 layer composites are assumed to be equal in the case when all layers have the same in-plane orientation. Although this statement is likely to be true for isotropic materials or even for unidirectional laminated composites, it may not be valid in some cases of woven composites.

This paper contains experimental and theoretical investigations of plain weave carbon fiber/polyester composites. Specimens with one single and eight layers of fabrics are tested and observable differences of mechanical properties are obtained.

The theoretical part of this article consists of derivation and application of several micromechanical models on these particular composites. The use of those simplified models finally allows us to find the main mechanisms which cause the observed effects.     

Micromechanically-based effective thermal conductivity estimates for polymer nanocomposites

The Effective Continuum Micromechanics Analysis Code was modified to predict the effective thermal conductivities of composites containing multiple distinct nanoheterogeneities (fibers, spheres, platelets, voids, etc.) each with an arbitrary number of coating layers based upon either the modified Mori–Tanaka or modified self-consistent methods for steady state heat conduction. A parametric study was performed to investigate the effect of nanoreinforcement morphology, volume fraction, orientation, and nanoreinforcement–resin interphase properties on calculated effective thermal conductivities. Predicted thermal conductivities matched experimentally measured values for vapor-grown carbon nanofiber/polypropylene, exfoliated graphite flake/epoxy, glass microsphere/polystyrene, cupric oxide sphere/epoxy, and aluminum sphere/epoxy composites.     

Effects of fabric parameters on the tensile behaviour of sustainable cementitious composites

The mechanical behaviour of fabric-reinforced composites can be affected by several parameters, such as the properties of fabrics and matrix, the fibre content, the bond interphase and the anchorage ability of fabrics. In this study, the effects of the fibre type, the fabric geometry, the physical and mechanical properties of fabrics and the volume fraction of fibres on the tensile stress–strain response and crack propagation of cementitious composites reinforced with natural fabrics were studied. To further examine the properties of the fibres, mineral fibres (glass) were also used to study the tensile behaviour of glass fabric-reinforced composites and contrast the results with those obtained for the natural fabric-reinforced composites. Composite samples were manufactured by the hand lay-up moulding technique using one, two and three layers of flax and sisal fabric strips and a natural hydraulic lime (NHL) grouting mix. Considering fabric geometry and physical properties such as the mass per unit area and the linear density, the flax fabric provided better anchorage development than the sisal and glass fabrics in the cement-based composites. The fabric geometry and the volume fraction of fibres were the parameters that had the greatest effects on the tensile behaviour of these composite systems.     

Press forming a 0/90 cross-ply advanced thermoplastic composite using the double-dome benchmark geometry

A pre-consolidated thermoplastic advanced composite cross-ply sheet comprised of two uniaxial plies orientated at 0/90° has been thermoformed using tooling based on the double-dome bench-mark geometry. Mitigation of wrinkling was achieved using springs to apply tension to the forming sheet rather than using a friction-based blank-holder. The shear angle across the surface of the formed geometry has been measured and compared with data collected previously from experiments on woven engineering fabrics. The shear behaviour of the material has been characterised as a function of rate and temperature using the picture frame shear test technique. Multi-scale modelling predictions of the material’s shear behaviour have been incorporated in finite element forming predictions; the latter are compared against the experimental results.