Introduction to Composites

Science & Engineering

Dr. Lukasz Figiel
International Institute for Nanocomposites Manufacturing (IINM),
WMG, University of Warwick
E-mail: l.w.figiel@warwick.ac.uk

Part 3

Engineering analysis of two-component composites

Predicting accurately a property of a composite is not an
easy task.
Photo-elastic analysis

Finite Element analysis

Non-uniform
distribution of strain in
the matrix under
transverse loading
High strain/stress
gradients near the
fibres

Source: T.W. Clyne

Source: ONERA

Reasonable predictions can be made for fibre composites,

by employing simplified assumptions about the stress and
strain distribution, and the rule of mixtures.
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Material composition Rule of Mixtures

Consider a block of a composite material (f: filler, m: matrix)

Clearly, total mass: m m f mm , total volume: v v f vm

Proportions of filler and matrix in the composite:
vf
vm v v f
f
m
1 f Volume fractions
and
v
v
v
3

Material composition Rule of Mixtures

Thus, the mass density of the composite:
m f v f m vm

f f 1 f m
v
v

Rule of Mixtures

is the sum of a volume fraction-weighted contributions of

the densities of fibre and matrix.
Remark: The above equation was derived based on the
assumption that there is no voids (e.g. air bubbles) in the
composite.
Void content: >2% means poor fabrication
<0.5% high-quality fabrication
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Example
A composite material is made of 60% (by weight) Kevlar 49
fibres in epoxy resin.
(1) Show that the weight-to-volume conversion is:

wf f

w f f 1 w f

mi
where wi
m

weight fraction of
the i-th component

(2) Find its volume fraction and density. Density of Kevlar and
epoxy can be found in Tables included in Lecture 1.
Ans. (1):

Ans. (2):

vf
v

mf f
m f f mm

f 0.574,

wf f
m

f m
w f f 1 w f

~ 1386 kg / m3

Prediction of tensile modulus

Consider a block of composite reinforced with uniaxially
aligned continuous fibres.
(1) Axial (longitudinal) modulus
If a stress () acts parallel to fibres direction, fibres and
matrix are coupled together in parallel, approximately.
matrix

fibre
Axial strains in the composite:

f m

Axial stresses in the composite:

f f 1 f m
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Prediction of tensile modulus

Hookes law:

f Ef f

Substituting for stresses:

Axial Youngs modulus:

and

m Em m

E1

E1 f E f f 1 f Em m
E1 f E f 1 f Em

(2) Transverse modulus

If a stress acts perpendicular
to fibres direction, the fibre
and matrix are approximately
coupled together in series.

f m

and

matrix

fibre

Prediction of tensile modulus

Transverse strains in the composite:

f f 1 f m

Using Hookes law:

Aligned glass
fibre/epoxy
composite

1 f 1 f

E2 E f
Em

Transverse Youngs modulus:

E2

E f Em

1 E
f

f Em
From Fig. 6.12, McCrum, Buckley, and Bucknall

Example
An E-glass fibre-thermoset polyester composite tube is
carefully constructed with the objective of achieving maximum
axial tensile modulus. The glass fibres are continuous and
highly aligned parallel to the tube axis. The tube contains 65%
(by volume) glass, and has dimensions: length 2m, diameter
100mm, and wall thickness 2mm. Predict the change in length
when the tube carries an axial tensile load of 15 kN.
Change in length: l 1 l0 ,
Hookes law (axial direction):
Axial modulus:

axial strain, l0 original length

1 E1 1

E1 f E f 1 f Em
= 0.65 76 109 0.35 3 109 50.45 109 Pa
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Example (contd)
F1
15 103
6

24.357

10
Pa
Axial stress: 1
2
2
A 0.05 0.048

24.357 106
4

4.8

10
Axial strain: 1
E1
50.45 109
Change in length:

l 9.6 104 m

Remark: Maximum strain (i.e. strain at failure):

Glass fibre:

1 mu fu

fu 2.8%

polyester matrix: mu

2%

the given tube operates safely under 15kN

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What if fibres are not uniaxially oriented?

Any misalignment of fibres causes the modulus to fall
below the value predicted by the rule of mixtures (i.e.
parallel coupling).

3
(a) Random fibre arrangement in two directions: E1 E2 Emax
8
(b) Random fibre arrangement in three directions: E1 E2 E3

1
Emax
5

(c) Fibres aligned at angle to axis 1:

Mohrs circle is
employed to find

E
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Strength of composites
(a) Tensile strength
Composite subject
to an arbitrary
state of stress

1u

Driven by the strength

of the fibre fu ,
especially at high
volume fractions
(depends on fibre and
matrix maximum
strains fu , mu )

(b) Transverse strength 2u

Driven by the strength
of the matrix mu

(c) Shear strength 12u

From Fig. 8.1, Hull and Clyne

Driven by the strength

of the interface and
shear strength of the
matrix
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Tensile strength of composites

if fu mu

1u

mu

fibres begin to break

if f is low :

1u 1 f mu

1u f fu (1 f ) mfu
Fibre

fu
1u

if f is high :

Composite

fu

Matrix

mu

f fu 1 f mfu

fu
mfu

fu

mu
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Simulation of composite strength

Transverse cracking (Scanning Electron Microscopy images)

Finite Element (FE) simulation of transverse cracking

Source: T. Vaughan
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Simulation of nanocomposite strength

Transmission Electron Microscopy

Molecular simulation

FE simulation

Source: Wang et al. Macromolecules, 2005.

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Summary
Engineering analysis of composite properties is not an
easy task due to a complex strain and stress distribution
within a composite
Rule of mixtures enable us to approximate composite
properties (e.g. density, axial Youngs moduli, axial
strength)
Composites failure is a complex sequence of events
(fibre fracture, matrix cracking, interface debonding)

More accurate predictions of failure behaviour can be

achieved by computer simulations, e.g. Finite Element
Method (FEM), validated by experiments
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