Multiscale model of micro curing residual stress evolution in carbon fiber-reinforced thermoset polymer composites
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RESEARCH ARTICLE
Xinyu HUI, Yingjie XU, Weihong ZHANG
Multiscale model of micro curing residual stress evolution in carbon fiber-reinforced thermoset polymer composites
© Higher Education Press 2020
Abstract In this study, the micro curing residual stresses of carbon fiber-reinforced thermoset polymer (CFRP) composites are evaluated using a multiscale modeling method. A thermochemical coupling model is developed at the macroscale level to obtain the distributions of temperature and degree of cure. Meanwhile, a representative volume element model of the composites is established at the microscale level. By introducing the information from the macroscale perspective, the curing residual stresses are calculated using the microscale model. The evolution of curing residual stresses reveals the interaction mechanism of fiber, matrix, and interphase period during the curing process. Results show that the curing residual stresses mostly present a tensile state in the matrix and a compressive state in the fiber. Furthermore, the curing residual stresses at different locations in the composites are calculated and discussed. Simulation results provide an important guideline for the analysis and design of CFRP composite structures. Keywords CFRP, curing residual stress, multiscale modeling, finite element method
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Introduction
Carbon fiber-reinforced thermoset polymer (CFRP) composites have been widely used in various applications, such as aeronautics and aerospace, automotive, and marine and Received January 8, 2020; accepted March 20, 2020
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Xinyu HUI, Yingjie XU ( ), Weihong ZHANG State IJR Center of Aerospace Design and Additive Manufacturing, School of Mechanical Engineering, Northwestern Polytechnical University, Xi’an 710072, China E-mail: [email protected] Yingjie XU Shaanxi Engineering Laboratory of Aerospace Structure Design and Application, School of Mechanical Engineering, Northwestern Polytechnical University, Xi’an 710072, China
civil engineering, due to its high specific stiffness and strength [1–3]. The autoclave curing process is a commonly used method in the manufacturing of CFRP composite parts of different industries [4,5]. In the curing process, the residual stresses invariably occur due to the mismatched thermal expansion between the fiber and matrix and the chemical shrinkage of the matrix. Curing residual stress is a critical defect that affects the mechanical performance of composite parts. For instance, the release of residual stresses results in shape distortion, that is, curing deformation [6]. In extreme cases, large residual stresses can even cause debonding in the fiber–matrix interphase and microcracks in the matrix before loading [7]. Therefore, investigating the evolution of curing residual stresses is important to understand the mechanical performance of final composite parts thoroughly. Several experimental methodologies have been used to measure the curing residual stresses in CFRP composites. For example, strain gauges [8,9] or fiber optic sensors [10] were embedded in composites to ch
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