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Analytical model for predicting the tensile strength of unidirectional composites based
on the density of fiber breaks
PII: S1359-8368(17)30696-0
DOI: 10.1016/j.compositesb.2017.12.012
Reference: JCOMB 5441
Please cite this article as: Vanegas-Jaramillo JD, Turon A, Costa J, Cruz LJ, Mayugo JA, Analytical
model for predicting the tensile strength of unidirectional composites based on the density of fiber
breaks, Composites Part B (2018), doi: 10.1016/j.compositesb.2017.12.012.
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Medellín, Colombia
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Grupo de Investigación Materiales y Energía, MATyER, Instituto Tecnológico Metropolitano, Medellín,
Colombia.
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*corresponding author email: juan.vanegas@udg.edu, Tel: (+57) 312 722 7380
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Abstract
While analytical fiber fragmentation models following the global load-sharing (GLS) assumption
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efficiently reproduce the stress strain curves of unidirectional composites loaded in the direction of the
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reinforcement when the number of breaks is moderate, they completely fail to predict tensile strength. In
this paper, we propose that failure takes place when a critical density of breaks, which depends entirely on
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the constituent properties, is reached. Therefore, we rewrite classic GLS fragmentation models in terms of
the linear density of breaks. The critical number of breaks for a set of glass and carbon reinforced
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polymer composites is extracted from published experimental data and fitted to an empirical law, with
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good predictive capability. Our approach complements GLS fragmentation models because it identifies
the ultimate stress, from which the stress-strain curve given by the model becomes unrealistic.
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Keywords
1 Introduction
laminates are fast tools for structural design and permit their constituents to be optimized for a better
mechanical performance. Analytical models for the stress-strain behavior of unidirectional plies in the
direction of the reinforcement rely on the representation of the stochastic occurrence of breaks along the
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Fragmentation models assume a stochastic distribution of defects along the fibers [3], (the Weibull
distribution is most commonly used), as well as a certain rule of load sharing from a broken fiber to the
rest of the composite. A useful baseline of results has been obtained by assuming that stress re-
distribution around fiber breaks satisfies the global load-sharing (GLS) assumption (i.e. that the load is
spread evenly among all the fibers in the composite) [4–6]. Under this condition, there is no interaction
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between fiber breaks of different fibers. These models aim to relate the remote uniaxial stress, , to the
strain, . Due to the stochastic nature of the phenomenon and the large number of fibers in the composite,
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it is assumed that the average stress built up along the fragmented fiber matches the average stress in a
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For instance, Curtin [8] deduced an analytical stress-strain solution by expanding the Weibull
distribution of the fiber strength with a Taylor series. Curtin’s model was later extended by Neumeister
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to consider the overlap of influence zones adjacent to fiber breaks [9,10]. Later, Hui and collaborators
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developed an exact solution for the fiber fragmentation problem [11], which needs to be solved
iteratively. Furthermore, Turon et al. [12] developed a progressive damage model for unidirectional
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composites laminates based on fiber fragmentation. These models show very similar behavior in the
stress-strain curves up to the maximum of the curve. From this point on, the curves deviate because of the
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different micro-mechanisms considered (fiber-matrix pullout and sliding, etc.) and the mathematical
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complexity involved. The model developed by Neumeister [10] is of practical interest because it
reproduces the tensile behavior of brittle-fiber composites without the need to solve differential equations
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While those models reasonably agree with the experimental stress-strain curve for a low
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density of breaks (before the maximum of the curve), there is considerable discrepancy between them
when predicting strength. First, in a GLS context, and in spite of the lack of physical grounds for this
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hypothesis, it is often assumed that strength corresponds to the maximum of the curve and so GLS models
largely overpredict the experimental strength. In fact, composite failure will take place when the number
of fiber breaks reaches such a high level that an avalanche of fiber failure events take place. Indeed, the
load released by fiber-break(s) is redistributed among the intact adjacent fibers to reestablish local load
equilibrium. The stress is intensified in the adjacent fibers, increasing the probability of neighboring
fibers fracturing and, hence, controlling the strength. Consequently, the way this concentration factor is
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modeled determines the accuracy of the predicted strength (i.e. the global load-sharing assumption is
Other types of models account for the stress concentrations around broken fibers and are generically
named Local Load Sharing (LLS) models [13–16]. They make use of complex mathematical formulations
[17,18] or numerical Monte-Carlo Simulations [19–22], although unlike the analytical GLS models, the
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computational cost of such models is very high and they do not lead to analytical expressions. In addition,
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Given the advantage GLS models have of being able to deliver fast results (allowing their use, for
example, in optimization iterative processes), there is interest in predicting composite strength within
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their framework. To achieve this, the composite strength must be related to a parameter delivered by the
GLS model. Koyanagi et al. [24] followed this approach and presented the Simultaneous Fiber-Failure
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(SFF) model, which assumes that the UD composite fails when a certain number (n) of simultaneous fiber
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breaks occur. This critical number of fiber breaks was deduced from the experimental strength of a set of
different composite materials and the fragmentation model. Then, for the composite materials considered,
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a phenomenological relationship was established between n and the strength ratio , where is
the interfacial strength between fiber and matrix, is the characteristic stress of the Weibull distribution
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of the fiber strength and is the strength of the matrix. The empirical relationship between and the
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ln = + ln + (1)
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Then, for an arbitrary system of known material parameters , and , equation 1 is used to estimate
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, which determines the ultimate tensile strength through the SFF model as follows:
%
&'%
+1 2 1 !" + − 1
= ∙ $
+2 +2 !"
(2)
where is the critical stress, is the Weibull coefficient and !" is the fiber volume fraction. The critical
stress is the theoretical stress that causes uniform fragment spacing in a single filament, in the moment
in which the fiber fragmentation process ceases. In practice, the composite would fail before reaching
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this stress. The critical stress controls several major composite properties such as tensile strength, fiber
with * being the characteristic length of the Weibull distribution and , the fiber diameter.
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Koyanagi et al. mixed, in a unique relationship (equation 1), different material systems such as glass and
carbon fiber-reinforced polymeric composites (GFRP, CFRP), ceramic matrix composites (CMC), and
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carbon/carbon composites (C/C). Although their predictions were reasonably accurate for C/C and CMC,
in the case of GFRP and CFRP it was much lower. While Koyanagi’s GLS-based model may have
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improved strength estimation accuracy, when compared to the predictions based on the maximum of the
curve, they are not particularly suitable for CFRP and GFRP.
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In this work, we propose an alternative approach to predict the strength of a unidirectional composite
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in a GLS fragmentation model framework. Our approach relies on assuming that failure will take place at
a critical crack density (i.e. number of breaks per unit length), which will be specific to each material
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system. To determine critical density, two different fragmentation models (Neumeister’s and Turon’s)
formerly formulated to relate the remote stress, , with the far-field fiber stress, ", were rewritten in
terms of the number of breaks per unit length, Λ , to yield the Λ curve. The critical number of
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for several CFRP and GFRP composites was evaluated using the current
model and data from the literature concerning their experimental strength. We observed clear trends in the
dependence of the critical number of breaks on the parameters of the system (fiber, matrix and interface
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Polymer matrices reinforced with structural fibers as carbon, glass or aramid (fiber-reinforced
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polymers or FRPs) possess excellent specific mechanical properties as strength and stiffness. As a result,
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structural composites are commonly used in applications driven by weight reduction in aerospace,
although they are continuously expanding to other industrial sectors, such as automotive, energy, sports or
civil engineering. Excellent examples of carbon composite applications in aerospace are found in the last
two civil airplanes developed by Airbus and Boeing, the A350 and 787 Dreamliner, respectively, in
which composites made up to 50 % in weight of structural parts ranging from fuselage barrels or wings to
stabilizers. However, despite the increasing number of engineering applications of structural composites,
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the accurate prediction of their mechanical behavior still remains an arduous task because of the
complexity of the failure mechanisms involved, specially at the microscopic level [26]. This kind of
studies can be faced using numerical methods and computational tools. However, they have a high
computational cost and time consuming. The present work offers a practical analytical tool of design that
allows accurately predicting the mechanical response of unidirectional reinforced polymers used on the
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above-mentioned applications.
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2 Fiber Fragmentation models
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When a tensile load in the direction of the reinforcement is applied monotonically to a composite,
fibers fail randomly at several flaws along the composite in question [27]. Around a fiber break, the load
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is transferred by the matrix and the fiber may slide (depending on the fiber/matrix interface). The stress
level on the fiber is fully recovered over a load transfer length *0 , due to the presence of the interfacial
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shear stress, [9,10]. The reinforcement is, thus, subjected to significant fragmentation prior to failure
[28] (Figure 1). Since any component made of such a composite contains a very large number of fibers,
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when the density of fiber breaks is low, the overall behavior of the material is described by the averaged
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value of the individual constituent’s behavior. Furthermore, by considering the stochastic response of the
reinforcement, the net stress over any cross-section of the composite containing enough contributing
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fibers can be obtained from the mean stress in a long (fragmented) fiber subjected to the same strain
[9,10].
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The probability of fracture for a fiber of length * under stress " is described by a Weibull distribution:
4 78 :
1 ", * =1− 2 5 75
3 6 9
4 (4)
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coefficient. Because of the loss of ability to carry the load involved in the fragmentation process, the
apparent stiffness of the system decreases with the number of breaks. The apparent axial stiffness of the
composite can be obtained from the number of fiber breaks, ; [43], which is assumed to follow a
Poisson Law:
* " &
= ) -
;
*
(5)
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Once the mean number of breaks is known, the distance between two breaks, i.e., the length of the
different fragments into which the fiber has split, can be computed as [29]
1 " &
Λ= = ) -
;
* *
(7)
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Considering the importance of the critical stress (3), the number of breaks per unit length (7) can be
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rewritten as [29]
1 &'%
Λ = ) -
"
2*0 (
(8)
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where the load transfer length or ineffective length, *0 is the interval required to build up the full fiber
*0 =
U ,∙
4∙
"
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(9)
Small ineffective lengths (small fiber diameters or high interfacial shear stress) create large stress
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concentrations in the neighboring fibers, thus raising the possibility of cumulative flaws leading to
fracture [30]. Large ineffective lengths increase the size of the flaw within the composite. Then, the
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interfacial shear stress, , plays a crucial role in the ultimate tensile strength of unidirectional composites
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[31]. All of these parameters (equations 5 to 9) are the base for defining the fragmentation models.
1 1 E
= !" ∙ D + 6 9 G
"
E+1 2∙F E+1 E+1
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@ABC
(10)
where E is a damage variable that accounts for the relationship between the load of the fiber, " , and the
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&'%
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E=) -
"
(11)
(
In the same way, Turon et al. [27] proposed an approximate analytic relationship for stress-strain
curve:
1 − 2 3M 1 4 78
:
3 6 9
= !" ∙ L + E ∙ 2 NO 7P Q
HBIJK "
E 2
(12)
where R equals twice the stress recovery region at the critical stress (.
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Furthermore, Hui et al. [11] obtained an equivalent expression for the approximation of the remote
tensile stress as
1 %
= !" ∙ D)1 + E + Θ ∙ E - 2 3M6%3VWM9 G
SBT "
2
(13)
where
X=
+1
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(14)
7 + 12
Θ=
24 2 + 3
(15)
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To compare the three above-mentioned fragmentation models, the predicted stress-strain curves for
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typical carbon and glass reinforced composites are depicted in Figure 2 by using (10), (12) and (13).
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Table 1. Weibull strength parameters for typical carbon-epoxy and glass-epoxy composites [4]
Material
Parameter
Carbon Fiber Glass Fiber
Characteristic strength,
Characteristic length, *
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50 MPa 50 MPa
The three models provide practically the same stress-strain behavior for low density of breaks before
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peak stress is reached. If the composite is assumed to fail when the stress-strain curve reaches peak stress,
the predicted strength largely exceeds the experimental values. This is because these models rely on the
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GLS assumption and so do not take into account local effects that will be predominant as the number of
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breaks increases. The following sections develop the idea that failure occurs when the composite reaches
3.1 Fiber fragmentation models in terms of the number of breaks per unit length
Fiber fragmentation can be understood as a progressive degradation process caused by the increase of
the number of fiber breaks as a load is monotonically applied. Then, the remote tensile stress given in
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equation (10) or (12) can be rewritten as a function of the number of breaks per unit length instead of the
%
" = Λ * & ∙ (16)
E = 2*0 ∙ Λ (17)
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And substituting (16) and (17) in (10), the Neumeister-CNB model becomes
%
= !" ∙ Λ * & ∙
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ghi 3 gj
1 1 2*0 ∙ Λ
(18)
∙L + Q
2*0 ∙ Λ + 1 2 ∙ F k 2*0 ∙ Λ + 1l 2*0 ∙ Λ + 1
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Similarly, the Turon-CNB model (12) results in
% 1 − 2 3 4q∙>
= !" ∙ Λ * ∙ ∙p + Λ*0 2 34J ∙> r
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&
min+o3 gj 2*0 ∙ Λ
(19)
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The corresponding expression for Hui’s model is not included here because it cannot be solved
explicitly and because, before maximum stress, the three models are similar. The models expressed in
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equations (18) and (19) relate composite stress with crack density (Figure 3). The overall stress evolution
of each composite is practically equal for both models until the peak of the curves is reached (this result is
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expected in view of the similarity of the models (Figure 2), and the fact that only a change of variables
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The approach proposed in this work relies on assuming that the ultimate stress of the composite
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corresponds to a critical density of fiber breaks characteristic of the material in question (volume fraction
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of fibers in the composite, fiber diameter, Weibull parameters of the fiber and interfacial shear strength).
A necessary additional assumption is that the Λ curves (equations 18 and 19) apply when the
critical density of fiber breaks is reached. This last assumption is somehow contradictory. On the one
hand, the fragmentation models (equations 18 and 19) follow a global load-sharing rule, so the interaction
between fiber breaks is not considered. On the other hand, the fracture of the composite occurs when a
critical crack density is reached, in which the interaction between fiber breaks is important enough to
create avalanches of broken fibers and eventually the collapse of the component. When a fiber breaks, the
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load on that fiber in locally relaxed and the fiber springs back. This creates a stress wave travelling along
each fiber, causing a temporary increase in the stress concentration [32]. Some authors have stressed the
importance of dynamic stress concentrations in the failure of unidirectional composites [33–37]. In fact,
the assumption is that as soon as the interaction between fiber breaks becomes important, the critical
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By admitting these hypotheses, the critical stress measured in an experimental test must correspond to
the stress predicted by the fragmentation models when the crack density reaches the critical crack density.
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Or, in other words, the critical crack density can be deduced from the measured ultimate stress by using
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We followed this approach to compute the critical number of breaks for seven CFRP and three GFRP
composites with different constituent properties and fiber volume fractions (Table 2). Composites 1 to 6
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in Table 2 are composites with different types of carbon reinforcements, all of which are embedded in
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epoxy (EP) resins. Item 7 corresponds to a carbon fiber and vinyl ester (VE) composite system.
Furthermore, composites 8 to 10, are materials reinforced with glass fibers in EP or VE matrices.
(
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On the other hand, we have extended the concept of the critical stress for a single fiber, (eq. 3, the
s
stress at which fiber fragmentation saturates), to the overall fragmentation limit stress, (, of the
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s
=
TE
!" (20)
s
(, which only depends on the constituent properties and the volume fraction, corresponds to the
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remote stress that, on average, causes a fragmentation saturation in all the fibers of the composite.
That is, the composite is not able to develop further fragmentation, so other damage mechanisms, such as
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fiber sliding and fiber pullout, among others, start to appear. This sequence of events is already
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evidenced in, for example, the Neumeister model (eq. 10). The equation has two softening terms: the first
corresponds to the contribution the intact fibers make to the overall stress within the composite (dashed
line in Figure 4), whereas the second accounts for the contribution the sliding and separation of the fibers
makes (dashed-dotted line in Figure 4). When the first term curve is close to reaching the peak,
fragmentation ceases, the sliding and separation of fibers becomes predominant and the failure of the
composite is imminent.
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Table 2. Constituent properties, experimental tensile strength, critical number of breaks and overall
fragmentation limit stress of several GFRP and CFRP composites systems.
No. 1 2 3 4 5 6 7 8 9 10
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CARBON
Fiber GLASS
T700SC AS400 T700 M40 AS-4 AS-4 M40
VINYL VINYL
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Matrix EPOXY EPOXY
ESTER ESTER
vw
0.300 0.300
0.590 0.700 0.600 0.677 0.677 0.300 0.567 0.100
0.400 0.400
xy
z1{
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230 294 220 392 234 234 392 76 72 72
|
μ~
6.9 7.1 7.0 6.0 7.1 7.1 6.0 13.0 14.9 16.0
•€
•1{
2700 4275 5470 4500 4275 4493 4500 1150 1649 2500
‚€
~~
100.0 12.5 20.0 25.0
U
12.7 10.0 25.0 24.0 5.0 25.0
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ƒ 9.03 10.30 5.60 16.0 10.7 8.33 16.0 6.34 3.09 13.0
„
•1{
23 40 40 50 40 40 20 42 23 40
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Ref. [38–40] [41] [41] [24] [42] [42] [24] [22] [38] [24]
•s…
12306,0 9871,9 13756,3 9955,0 8524,4 9374,0 18550,8 3956,3 7497,6 33059
D
MPa
tu 1055 1890 3409 2310 1890 1890 1390 940 719 252
MPa
TE
†…
131.9E-4 41.2E-4 269.4E-4 43.5E-4 8.2E-4 19.0E-4 1520.9E-4 10283.5E-4 5168.0E-4 529.6E-4
1/mm
Consequently, the critical number of breaks per unit length Λ‡ and the overall fragmentation limit
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stress s
, point to the same stage in the loading of the composite: the transition from fragmentation to
the final failure of the composite. Their mutual dependence shown for the materials included in Table 2,
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demonstrates distinct behaviors for CFRP and GFRP composites (Figure 5). For CFRP (dashed-dotted
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we fitted the relationship between them by using the following empirical equation:
‰
Λ‡ = 2 ∙k7Ô l 'Š∙k7Ô l'( (21)
where the parameters {, ‹ and Œ for each material (Table 3) were determined by a second order
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Table 3. Estimation of the parameters of the critical number of breaks model (CNB) for carbon
and glass fiber reinforced composites
{ ‹ Œ
Coefficient
Fiber
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As can be observed in Figure 5, the curves for CFRP and GFRP present different trends, with the first one
monotonically increasing and the other one, monotonically decreasing. A possible way to give an
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explanation to the different trends observed is to analyze independently the influence of the different
parameters ([" , + , *+ …) on the critical stress and the associated critical density of breaks. However,
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using the experimental data available, it is difficult to perform this analysis and provide a conclusive
explanation. This analysis can be done, for example, using detailed micro-mechanical models and will be
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addressed by the authors in the near future.
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4 Discussion
Applying the CNB model to (Table 2) material 2, AS400 carbon fiber embedded in an epoxy matrix,
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is used to discuss the proposed procedure and to compare the predicted composite strength using two
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alternative approaches: the maximum of the stress-strain curve, MAX, and the Simultaneous Fiber
Both Neumeister’s (10) and Turon’s (11) fragmentation models provide the same stress-strain curve
before its maximum, so they can be used equivalently to predict the strength (Figure 6). The measured
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tensile strength of AS400/Epoxy is Su = 1890 MPa. The material has a critical stress of σ( =
5824.5 MPa which, considering the fiber volume content !" = 0.590, leads to an overall fragmentation
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limit stress of s
= 9872.11 MPa. Then, the corresponding critical number of breaks according to the
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empirical relationship of the equatio1n (21) is Λ‡ = 4.12[ − 3 ~~3% . Using (18) or (19), this critical
Then, the error in the CNB value, with regards the experimental one, is ˜ gj = 2.85%. The error is
obviously small as this material is one of the seven CFRP materials used to fit Equation (21).
On the other hand, using Koyanagi’s SFF model with a matrix strength of = 80 MPa (normal
epoxy resin strength [24]), the number of fibers that fail simultaneously and the predicted ultimate
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Finally, the maximum of the curve, (MAX, Figure 6) using the Neumeister model (10) gives a tensile
The ultimate stress prediction, according to the CNB, SFF and MAX models, for all the materials in
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Table 2 is illustrated in Figure 7. These results show the suitability of the number of breaks parameter in
identifying where in the fragmentation curve composite failure will take place. Fragmentation models
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based on the GLS rule extend continuously up to practically unattainable strains. The ability to locate the
point in the GLS curve where the material fails complements and enhances the usefulness of the
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fragmentation models to support structural design and/or optimize the constituent properties for an
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A GLS fragmentation model has clear advantages in terms of readiness of implementation and
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delivery of outputs, although it does have intrinsic limitations. For instance, the fact that GLS models do
not account for stress concentrations around fiber breaks rules out their ability to capture size scaling
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The predictive accuracy for composites other than those explored in Table 2, remains an open
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question, especially if more ductile matrices are considered, where the stress redistribution near a fiber
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break can be very different. We would have liked to have included other CFRP or GFRP composites
(different fibers and matrices) in this study to challenge the validity of the phenomenological CNB model.
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However, the mechanical properties of the constituents required to calculate the overall fragmentation
s
limit stress, (, are difficult to determine experimentally with confidence [43] and are scarcely found in
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framework are a more controlled scenario where the effect of the constituent properties on the ultimate
strength can be investigated. In spite of the high computational cost associated to analyzing the
fragmentation of a relevant number of fibers, this remains an ongoing research activity carried out in the
author’s laboratory.
5 Conclusions
Neumeister’s and Turon’s global load-sharing (GLS) fragmentation models have been reformulated to
express composite remote stress in terms of the number of breaks per unit length. We propose that
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composite failure, which cannot be directly captured by GLS models, takes place at a critical number of
breaks per unit length which, in turn, depends on the properties of the constituents and the volume
A set of CFRP and GFRP materials found in the literature, including the data for constituent
properties and ultimate stress, has been used to deduce an empirical law for the critical number of breaks
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as a function of the overall fragmentation limit stress, which depends solely on the material properties and
fiber volume fraction. While the empirical law shows differing behavior for CFRP and GFRP, there are
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clear tendencies for each of them. For the materials considered, the CNB model better predicts the
strength when compared to other approaches previously published in the literature. However, the model’s
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accuracy for other materials requires further investigation.
The CNB approach complements GLS fragmentation models by adding the capability to identify the
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ultimate stress in the stress strain curve.
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Acknowledgements
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This work was supported by Administrative Department of Science, Technology and Innovation,
year 2015].
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Figure 1. Stress profile at a fragment of a broken fiber
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Figure 2. Comparison of fragmentation models for typical carbon/epoxy and glass/epoxy composites
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Figure 3. Comparison of fragmentation models based on the number of breaks per unit length for typical
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Figure 4. Decomposition of the stress-strain curve according to the predominant damage phenomena of a
CFRP composite using Neumeister’s model
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Figure 5. Relationship between the critical number of breaks per unit length œ( and the overall
fragmentation limit stress ( ′
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Figure 6. Predicted and experimental mechanical response for AS400/Epoxy composite using
Neumeister’s, Turon’s and CNB models
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Figure 7. Comparison of the predicted strength, using CNB, SFF and MAX models, with the
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(1) T700-EP
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Experimental
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(8) Glass-EP