An integrated computational materials engineering framework to analyze the failure behaviors of carbon fiber reinforced polymer composites for lightweight vehicle applications

Abstract

A bottom-up multi-scale modeling approach is used to develop an Integrated Computational Materials Engineering (ICME) framework for carbon fiber reinforced polymer (CFRP) composites, which has the potential to reduce development to deployment lead time for structural applications in lightweight vehicles. In this work, we develop and integrate computational models comprising of four size scales to fully describe and characterize three types of CFRP composites. In detail, the properties of the interphase region are determined by an analytical gradient model and molecular dynamics analysis at the nano-scale, which is then incorporated into micro-scale unidirectional (UD) representative volume element (RVE) models to characterize the failure strengths and envelopes of UD CFRP composites. Then, the results are leveraged to propose an elasto-plastic-damage constitutive law for UD composites to study the fiber tows of woven composites as well as the chips of sheet molding compound (SMC) composites. Subsequently, the failure mechanisms and failure strengths of woven and SMC composites are predicted by the meso-scale RVE models. Finally, building upon the models and results from lower scales, we show that a homogenized macro-scale model can capture the mechanical performance of a hat-sectionshaped part under four-point bending. Along with the model integration, we will also demonstrate that the computational results are in good agreement with experiments conducted at different scales. The present study illustrates the potential and significance of integrated multi-scale computational modeling tools that can virtually evaluate the performance of CFRP composites and provide design guidance for CFRP composites used in structural applications.

Multiphysics Modeling and Numerical Simulation in Computer-Aided Manufacturing Processes

“…It was found that the regions that undergo plastic deformation (grey color) are located in the thin cross sections in the FEM solid model, whereas they are much more extended towards the junctions in the FEM beam model (Figure 3). Sun et al [63] developed an Integrated Computational Materials Engineering (ICME) framework (Figure 4) to analyze the failure behavior of carbon fiber reinforced polymer (CFRP) composites used for lightweight vehicle applications. The properties of the interphase region have been determined by a molecular dynamics analysis and the analytical gradient model.…”

A review of FMLs performance test methods and index evaluation

“…According to the main problems of the macroscopic simulation study, a variety of strength failure theories are also put forward. However, the macroscopic simulation does not involve the micro mechanism of material failure, but predicts the failure behavior of the composite material structure through the material failure criteria [137][138][139]. Therefore, the macroscopic simulation is widely used in engineering practice and plays an important role.…”

Improvements in Temperature Uniformity in Carbon Fiber Composites during Microwave-Curing Processes via a Recently Developed Microwave Equipped with a Three-Dimensional Motion System

“…Carbon-fiber-reinforced polymer (CFRP) composites with a high strength-to-weight ratio, stiffness-to-weight ratio, and corrosion resistance have gained substantial interest in numerous fields, such as aerospace, automobiles, sporting goods [ 1 ], etc. In the automotive industry, CFRP is one of the most promising alternatives to engineered metals for lightweight automotive structural components [ 2 , 3 , 4 , 5 ], and its demand has increased with the booming development of electric vehicles (EV) in recent years since lightweight designs comprise effective methods for optimizing the mileage of EV [ 6 , 7 ]. However, due to the low through-thickness thermal conductivity of CFRP [ 8 ], as well as the demand for homogeneous temperature distributions during the entire curing process for producing the desired part quality, the curing process of the CFRP normally features long processing times and high energy consumption, especially when this process is carried out in autoclaves.…”