Thermoplastics reinforced with continuous fibers are very promising building materials for the auto industry and consumer electronics to reduce the weight of vehicles and portable devices, and to deliver a high impact tolerance at the same time. Polypropylene is an abundant thermoplastic, and its glass fibers composites make a valuable solution that is suitable for mass production. But the adoption of such composites requires a deep understanding of their mechanical behavior under the relevant loading conditions. In this Ph.D. work, we aim to understand the damage process in continuous glass fiberreinforced polypropylene in detail. We will focus in particular on developing an approach for microscale observation of damage during the out-of-plane loading process and will use these observations for both qualitative and quantitative evaluation of the composite. We will apply our approach to two kinds of polypropylene composites, one of them is specially designed to withstand impact. The comparison between the two types of composites at slow and fast loading cases will shed some light on the effect of the polymer properties on the behavior of composites under out-of-plane loading.

The present study investigates microcracking and damage progression in IM7/977-2, IM7/5555, and IM7/5276-1 [0/90/90/0] laminates. For each material system, seven to eight small coupons were axially loaded in a tensile substage. At increments of around 50 MPa the surfaces of the specimens were inspected via optical microscopy so that a history of microcracking damage as a function of applied loading could be charted. In the IM7/977-2 laminates microcracks were found to initiate on average at around 1050MPa; microcracking initiation for the other two systems was around 850 to 900 MPa. Also, the IM7/977-2 system displayed a steeper increase in crack density as a function of applied loading than the other two systems. The IM7/5555 system was the only system that achieved a microcracking saturation density; the saturation density was found to be around 17 cracks per centimeter. While the IM7/977-2 and IM7/5276-1 systems typically broke into two pieces at failure, the IM7/5555 specimens shattered into pieces. In addition, delaminations were observed in a majority of the IM7/5555 specimens at loadings 250MPa under the failure loads.

The goal of this research was to investigate the tensile fatigue behavior of a carbon fiber / epoxy composite material. Specifically, the stress levels at which cracks initiated in static and fatigue loading in the 90 degree plies of a "quasi-cross ply layup" [0/905]S was investigated. For layups which contain them, cracks in composite laminates initiate and propagate from 90 degree plies (including the ubiquitous "quasi-isotropic layup" 0/±45/90). Thus, this work provides valuable insight into the fatigue behavior of the plies which originate fatigue damage. Unidirectional off-axis 90 degree and 10 degree specimens were also tested, but the bulk of testing was done on the cross-ply laminates. The project sponsors, Boeing, were in the process of extending a failure model to the case of fatigue. The body of work presented here provided empirical data for that effort. Several different inspection techniques were used to investigate for cracking in the 90 degree plies, including: x-ray images, edge replicates, dye penetrants, and optical microscopy. Plots of the stress level at which crack initiation occurred will be presented, as well as images illustrating damage development in these layups. Comparisons are made to the experimental results of other investigations of this type of layup. Explorations of the effect of R-ratio (including R = 0.1 and 0.5), loading frequency (including 3, 10, and 30 Hz), and surface roughness (hand polished specimen edges to 1500 grit smoothness) on fatigue crack initiation were also performed. For the most damaging case (10 Hz, R = 0.1, no polishing), the crack initiation strain (0.00276) was one half of the strain at which cracks initiated in static monotonic loading (0.0054), and was 16% of the cross-ply specimen's (0 degree fiber dominated) ultimate strain value of (0.018).

Transverse ply cracking often leads to the loss of stiffness and reduction in thermal expansion coefficients. This paper presents the thermoelastic degradation of general cross-ply laminates, containing transverse ply cracks, subjected to biaxial extension, bending and thermal loading. The stress and displacement fields are calculated by using the state space equation method [Zhang D, Ye JQ, Sheng HY. Free-edge and ply cracking effect in cross-ply laminated composites under uniform extension and thermal loading. Compos Struct [in press].]. By this approach, a laminated plate may be composed of an arbitrary number of orthotropic layers, each of which may have different material properties and thickness. The method takes into account all independent material constants and guarantees continuous fields of all interlaminar stresses across interfaces between material layers. After introducing the concept of the effective thermoelastic properties of a laminate, the degradations of axial elastic moduli, Poisson¿s ratios, thermal expansion coefficients and flexural moduli are predicted and compared with numerical results from other methods or available test results. It is found that the theory provides good predictions of the stiffness degradation in both symmetric and antisymmetric cross-ply laminates. The predictions of stiffness reduction in nonsymmetric cross-ply laminates can be used as benchmark test for other methods.

<p>  </p> <p>Thermal shrinkage in advanced composite manufacturing causes residual stress in a cylindrical anisotropic segment. The residual stress later induces a spring-in angle when  the temperature change is negative. The superposition method in the finite element method (FEM) by ABAQUS©  proves that only the residual stress in the circumferential direction controls the spring-in angle and induces the radial residual stress. To predict the angle change, the residual stress is firstly determined by using the closed-loop geometry in FEM and then implemented into the cylindrical cross-ply symmetric laminate segment. Consequently, the geometry creates the spring-in angle under the traction-free surface. The angle change is in good agreement with the Radford equation and is found to depend on the coefficient of thermal expansion (CTE) in the circumferential and radial directions rather than other material properties and geometry dimensions. </p> <p>The study found a new limitation of the Radford equation, in that it is accurate when the part is anisotropic symmetric laminate, but not when it is unsymmetric. The accuracy of the Radford equation is further explored with the double curve geometry. Using the superposition method, the circumferential residual stress along the major curve is found to have an influence on the angle change not only of the major curve, but also of the minor curve. The negative temperature change produces the spring-in angle on the major curve, and both spring-in and -off angles on the minor curve, which rely on the radius ratio. In addition, the spring-in angle on the major curve is coincident with the Radford equation. In sum, knowing the spring-in angle is very helpful in designing a tool in advanced composite manufacturing, and the superposition method and the Radford equation are applicable to predict the spring-in angle.</p>

Transverse ply cracking often leads to the loss of stiffness and reduction in thermal expansion coefficients. This paper presents the thermoelastic degradation of general cross-ply laminates, containing transverse ply cracks, subjected to biaxial extension, bending and thermal loading. The stress and displacement fields are calculated by using the state space equation method [Zhang D, Ye JQ, Sheng HY. Free-edge and ply cracking effect in cross-ply laminated composites under uniform extension and thermal loading. Compos Struct [in press].]. By this approach, a laminated plate may be composed of an arbitrary number of orthotropic layers, each of which may have different material properties and thickness. The method takes into account all independent material constants and guarantees continuous fields of all interlaminar stresses across interfaces between material layers. After introducing the concept of the effective thermoelastic properties of a laminate, the degradations of axial elastic moduli, Poisson's ratios, thermal expansion coefficients and flexural moduli are predicted and compared with numerical results from other methods or available test results. It is found that the theory provides good predictions of the stiffness degradation in both symmetric and antisymmetric cross-ply laminates. The predictions of stiffness reduction in nonsymmetric cross-ply laminates can be used as benchmark test for other methods.

This study focuses on the response of flat unsymmetric laminates to an inplane compressive loading that for symmetric laminates are of sufficient magnitude to cause bifurcation buckling, postbuckling, and secondary buckling behavior. In particular, the purpose of this study is to investigate whether or not the concept of bifurcation buckling is applicable to unsymmetric laminates. Past work by other researchers has suggested that such a concept is applicable for certain boundary conditions. The study also has as an objective the determination of the response of flat unsymmetric laminates if bifurcation buckling does not occur. The finite-element program ABAQUS is used to obtain results, and a portion of the study is devoted to becoming familiar with the way ABAQUS handles such highly geometrically nonlinear problems, particularly for composite materials and particularly when instabilities and dynamic behavior are involved. Familiarity with the problem, in general, and with the use of ABAQUS, in particular, is partially gained by considering semi-infinite unsymmetrically laminated cross- and angle-ply plates, a one-dimensional problem that can be solve in closed form and with ABAQUS by making the appropriate approximations for the infinite geometry. In this portion of the study it is found that semi-infinite cross-ply laminates with clamped boundary conditions and semi-infinite angle-ply plates with simple-support boundary conditions remain flat under a compressive load until the load magnitude reaches a certain level, at which time the out-of-plane deflection become indeterminate, essentially an eigenvalue problem as encountered with classic bifurcation buckling analyses. Obviously, a linear analysis of such problems would not reveal this behavior and, in fact, there are other revealed significant differences between the predictions of linear and nonlinear analyses. Transversely-loaded and inplane-loaded finite isotropic plates are studied by way of semi-closed form Rayleigh-Ritz-based solutions and ABAQUS in a step to approaching the problem with unsymmetric laminates. A method to investigate the unloading behavior of postbuckled finite isotropic plates is developed that reveal multiple plate configurations in the postbuckled region of the response, and this method is then extended to the study of finite inplane-loaded unsymmetric laminates. To that end, two specific laminates, a symmetric and an unsymmetric cross-ply laminates, and a variety of boundary conditions are used to study the response of inplane-loaded unsymmetric laminates. The symmetric laminate is included to provide a familiar baseline case and a means of comparison. Plates with all four edges clamped and a variety of inplane boundary conditions are studied. Of course the symmetric cross-ply laminate exhibits bifurcation behavior, and when the tangential displacement on the loaded edges and the normal displacement on the unloaded edges are restrained, secondary buckling behavior occurs. For the unsymmetric cross-ply laminate, bifurcation buckling behavior does not occur unless the tangential displacement on the loaded edges and the normal displacement on the unloaded edges are restrained, or the tangential displacement on the loaded edges and the normal displacement on the unloaded edges are free. If either of these conditions are not satisfied, the unsymmetric cross-ply laminate exhibits what could be termed 'near-bifurcation' behavior. In all cases rather complex behavior occurs for high levels of inplane load, including asymmetric postbuckling and secondary buckling behavior. For clamped loaded edges and simply-supported unloaded edges, bifurcation buckling behavior does not occur unless the tangential displacement on the loaded edges and the normal displacement on the unloaded edges are restrained. For this case, rather unusual asymmetric bifurcation and associated limit point behavior occur, as well as secondary buckling. This is a very interesting boundary condition case and is studied further for other unsymmetric cross-ply laminates, including the use of a Rayleigh-Ritz-based solution in attempt to quantify the problem parameters responsible for the asymmetric response. The overall results of the study have led to an increased understanding of the role of laminate asymmetry and boundary conditions on the potential for bifurcation behavior, on the response of the laminate for loads beyond that level. / Ph. D.

O pneu é o único vínculo entre o veículo e o solo, é ele que transmite toda a potência e carga, e garante a dirigibilidade e condução do automóvel. A estrutura resistente de um pneu é um dos pontos de maior importância para o rendimento, tipo de aplicação e segurança. E conhecê-la é condição primária para o projeto. Pneus convencionais, via de regra, apresentam uma estrutura par de lonas cruzadas (cross-ply), dispostas em ângulos opostos, menores que 90º. Este trabalho visa avaliar as influências de uma estrutura ímpar de lonas cruzadas, em pneus convencionais. Objetiva-se com isso uma redução na matéria prima e uma otimização no tempo de processo. As influências da estrutura ímpar foram verificadas através de uma análise de elementos finitos, examinando o andamento das tensões internas na carcaça do pneu e observando a geometria da região de contato pneu/solo. Verificou-se também a variação da uniformidade utilizando-se do ensaio SAE J332 em uma máquina Akron FD90. A utilização de uma estrutura ímpar, em pneus de lonas cruzadas, acarreta numa deformação na região de contato pneu/solo, devido ao desbalanceamento de tensões nos fios da carcaça, um aumento das componentes de ply-steer e uma variação de força lateral nas componentes dinâmicas avaliadas. A utilização de uma estrutura ímpar deve ser cuidadosamente selecionada dependendo da velocidade, severidade e condições de utilização. / The tire is the only bond between the vehicle and the ground, is it that transmits all the power and load, and guarantees the driven and conduction of the automobile. The resistant structure of a tire is one of the most important factors for the efficiency, type of application and security. Knowing these parameters is the primary condition to design a tire. Conventional tires, usually have a pair structure, made of crossed plies (cross-ply) in opposite angles lesser than 90º. The present work aim to evaluate the influence of an odd cross-ply structure, in conventional tires, looking forward to a material reduction and also an optimization on time process. The influence of an odd structure was evaluated through a finite element analysis, examining the cord stress at the tire carcass and the tire/ground contact region (foot-print). The variation of the uniformity was also verified through a SAE332 test did on Akron FD90 machine. It was observed that the use of an odd structure in cross-ply tires cause a tire/ground contact region deformation, because of the unbalance internal cord stress (at the carcass), and an increase of uniformities components (ply-steer and variation of lateral force). The use of an odd structure must be carefully selected, depending on the speed, severity and condition of use.

O pneu é o único vínculo entre o veículo e o solo, é ele que transmite toda a potência e carga, e garante a dirigibilidade e condução do automóvel. A estrutura resistente de um pneu é um dos pontos de maior importância para o rendimento, tipo de aplicação e segurança. E conhecê-la é condição primária para o projeto. Pneus convencionais, via de regra, apresentam uma estrutura par de lonas cruzadas (cross-ply), dispostas em ângulos opostos, menores que 90º. Este trabalho visa avaliar as influências de uma estrutura ímpar de lonas cruzadas, em pneus convencionais. Objetiva-se com isso uma redução na matéria prima e uma otimização no tempo de processo. As influências da estrutura ímpar foram verificadas através de uma análise de elementos finitos, examinando o andamento das tensões internas na carcaça do pneu e observando a geometria da região de contato pneu/solo. Verificou-se também a variação da uniformidade utilizando-se do ensaio SAE J332 em uma máquina Akron FD90. A utilização de uma estrutura ímpar, em pneus de lonas cruzadas, acarreta numa deformação na região de contato pneu/solo, devido ao desbalanceamento de tensões nos fios da carcaça, um aumento das componentes de ply-steer e uma variação de força lateral nas componentes dinâmicas avaliadas. A utilização de uma estrutura ímpar deve ser cuidadosamente selecionada dependendo da velocidade, severidade e condições de utilização. / The tire is the only bond between the vehicle and the ground, is it that transmits all the power and load, and guarantees the driven and conduction of the automobile. The resistant structure of a tire is one of the most important factors for the efficiency, type of application and security. Knowing these parameters is the primary condition to design a tire. Conventional tires, usually have a pair structure, made of crossed plies (cross-ply) in opposite angles lesser than 90º. The present work aim to evaluate the influence of an odd cross-ply structure, in conventional tires, looking forward to a material reduction and also an optimization on time process. The influence of an odd structure was evaluated through a finite element analysis, examining the cord stress at the tire carcass and the tire/ground contact region (foot-print). The variation of the uniformity was also verified through a SAE332 test did on Akron FD90 machine. It was observed that the use of an odd structure in cross-ply tires cause a tire/ground contact region deformation, because of the unbalance internal cord stress (at the carcass), and an increase of uniformities components (ply-steer and variation of lateral force). The use of an odd structure must be carefully selected, depending on the speed, severity and condition of use.

Cross-ply composite laminates can develop very high density of transverse cracks in the 90-layer under severe thermal and mechanical loading conditions. At such high crack densities, two adjacent cracks start to interact, and a stress gradient is created in the region between these cracks. Due to the presence of high stress gradients, thickness averaging of longitudinal stress becomes obsolete. Thus, a detailed analysis of stress state along the thickness direction becomes necessary to study growth conditions of fiber sized microcracks initiated at the interface between 0-layer and 90-layer. Stress analysis at various crack densities is carried out in this project using finite element analysis or FEM as the main tool. This analysis is coupled with strain energy release rate (ERR) studies for a microcrack which grows in transverse direction from one interface to the other. The growth of this microcrack is found to be strongly influenced by the stress gradients and a presence of compressive stresses along midplane under tensile loading conditions at high crack densities.