Predictions of the axial tensile property of the unidirectional composite influenced by microfiber breakage defects

This paper primarily investigated the effect of fiber breakage defects on tensile properties of the unidirectional composite (UD) using the numerical simulation method. Different kinds of fiber breakage defects were firstly proved to exist in the UD according to the sub-micro computed tomography images at the microscale level. A strict random uniform distribution hypothesis was then proposed to introduce fiber breakage defects into the composite. Numerous microstructural models within random fiber breakage defects were created with the Monte Carlo method to analyze the fiber breakage defect effect on the UD. The results show that the tensile modulus of the UD was reduced by 17% when the fiber breakage defect volume fraction was only 1%, which indicates the effect of this kind of defect was very significant. The fiber volume fraction, defect volume fraction and property all have influences on the decrease of the UD caused by the fiber breakage defect. Finally, we derived a mathematical model to calculate the tensile modulus of the UD based on the numerical results. The proposed mathematical model has an application on the prediction of the axial modulus of the UD or the fiber tow containing large numbers of fiber breakage defects in the composites with complicated structure.

The Low Breaking Fiber Mechanism and Its Effect on the Behavior of the Melt Flow of Injection Molded Ultra-Long Glass Fiber Reinforced Polypropylene Composites

In this study, fiber breaking behavior, fiber orientation, length variation, and changes in melt flow ability of long glass fiber reinforced polypropylene (L-FRP) composites under different mold cavity geometry, melt fill path, and plasticization parameters were investigated. The matrix material used was polypropylene and the reinforcement fibers were 25 mm long. An ultra-long-fiber composite injection molding machine (with a three-stage plunger and injection mechanism design) was used with different mold cavity geometry and plasticization parameters. Different screw speeds were used to explore the changes in fiber length and to provide a reference for setting fiber length and parameter combinations. Flow-length specimen molds with different specimen thickness, melt fill path, and gate design were used to observe the effect of plasticizing properties on the flow ability of the L-FRP composite materials. The experimental results showed that the use of an injection molding machine with a mechanism that reduced the amount of fiber breakage was advantageous. It was also found that an increase in screw speed increased fiber breakage, and 25 mm long fibers were shortened by an average of 50% (to 10 mm). Long fibers were more resistant to melt filling than short fibers. In addition, the thickness of the specimen and the gate design were also found to affect the filling process. The rounded angle gate and thick wall product decreased the flow resistance and assisted the flow ability and fiber distribution of the L-FRP injection molding.

A Thermodynamic Framework for Stretching Processes in Fiber Materials

Fiber breakage process involves heat exchange with the medium and energy dissipation in the form of heat, sound, and light, among others. A purely mechanical treatment is therefore in general not enough to provide a complete description of the process. We have proposed a thermodynamic framework which allows us to identify new alarming signals before the breaking of the whole set of fibers. The occurrence of a maximum of the reversible heat, a minimum of the derivative of the dissipated energy, or a minimum in the stretching velocity as a function of the stretch can prevent us from an imminent breakage of the fibers which depends on the nature of the fiber material and on the load applied. The proposed conceptual framework can be used to analyze how dissipation and thermal fluctuations affect the stretching process of fibers in systems as diverse as single-molecules, textile and muscular fibers, and composite materials.

Prediction of fiber breakage and matrix cracking in polymeric composites under low-cycle fatigue regimes by fuzzy and wavelet clustering of acoustic emission signals

One of methods for detecting cracks and estimating their growth in materials such as composites is the acoustic emission technique. The detection of damages, cracks and their growth in industrial composite structures, under static and dynamic loads, has a significant importance, in order to prevent any damages and increase the reliability. Therefore, achieving required technical knowledge in this field, can be helpful in repairing and the maintenance of the part in industries. The prediction of the damage in polymeric composites under static loads has been already investigated by researchers; however, under cyclic loadings, researches about this behavior are still rare. In this study, by acoustic emission sensors and analyzing experimental data, the damage, including matrix cracking, the fiber breakage and other damages (debonding, fiber pull-out and delamination) during dynamic loading was investigated. At the first stage, standard specimens were made by the pure resin epoxy and the pure carbon fiber, subjected to monotonic tensile loading and then, the frequency of the failure was extracted. Then, composite specimens were loaded in the low-cycle fatigue regime. Mechanical test results and acoustic emission data were analyzed by fuzzy C-Means and wavelet transform methods and then compared to each other to find the percentage of failures in first, mid- and last cycles by the differentiation of failure types. Results clearly indicated that the acoustic emission approach is useful and an effective tool for identifying and detecting damages in polymeric composites.

Prediction of fiber breakage and matrix cracking in polymeric composites under low-cycle fatigue regimes by fuzzy and wavelet clustering of acoustic emission signals

One of methods for detecting cracks and estimating their growth in materials such as composites is the acoustic emission technique. The detection of damages, cracks and their growth in industrial composite structures, under static and dynamic loads, has a significant importance, in order to prevent any damages and increase the reliability. Therefore, achieving required technical knowledge in this field, can be helpful in repairing and the maintenance of the part in industries. The prediction of the damage in polymeric composites under static loads has been already investigated by researchers; however, under cyclic loadings, researches about this behavior are still rare. In this study, by acoustic emission sensors and analyzing experimental data, the damage, including matrix cracking, the fiber breakage and other damages (debonding, fiber pull-out and delamination) during dynamic loading was investigated. At the first stage, standard specimens were made by the pure resin epoxy and the pure carbon fiber, subjected to monotonic tensile loading and then, the frequency of the failure was extracted. Then, composite specimens were loaded in the low-cycle fatigue regime. Mechanical test results and acoustic emission data were analyzed by fuzzy C-Means and wavelet transform methods and then compared to each other to find the percentage of failures in first, mid- and last cycles by the differentiation of failure types. Results clearly indicated that the acoustic emission approach is useful and an effective tool for identifying and detecting damages in polymeric composites.

Impact of MTA blend % in melt spinning process and polyester properties

In Polyethylene terephthalate (PET) processing the raw materials are purified terephthalic acid (PTA), moderately purified terephthalic acid (MTA), monoehalene glycol (MEG). The processing of PTA is very difficult and costly. For reducing PTA percent we are using different percentages of MTA blend in PET processing. MTA affected the properties of polyester and melt spinning process. The properties such as elongation, tenacity, molecular chain length, b-color and IV, thermal properties, % carboxyl groups will change with MTA percentage. MTA percentage also affects fiber breakage percentage s, the melting point of PET. FTIR results show a change in chemical composition. Particle size, 4-CBA content of MTA affects the properties of the fiber.