Effect of Manufacturing on the Transverse Response of Polymer Matrix Composites

The effect of residual stress build-up on the transverse properties of thermoset composites is studied through direct and inverse process modeling approaches. Progressive damage analysis is implemented to characterize composite stiffness and strength of cured composites microstructures. A size effect study is proposed to define the appropriate dimensions of Representative Volume Elements (RVEs). A comparison between periodic (PBCs) and flat (FBCs) boundary conditions during curing is performed on converged RVEs to establish computationally efficient methodologies. Transverse properties are analyzed as a function of the fiber packing through the nearest fiber distance statistical descriptor. A reasonable mechanical equivalence is achieved for RVEs consisting of 40 fibers. It has been found that process-induced residual stresses and fiber packing significantly contribute to the scatter in composites transverse strength. Variation of ±5% in average strength and 18% in standard deviation are observed with respect to ideally cured RVEs that neglect residual stresses. It is established that process modeling is needed to optimize the residual stress state and improve composite performance.

Modeling and Analysis of the Composite Stiffness for Angular Contact Ball Bearings

As a core component of the motorized spindle, the dynamic stiffness of the angular contact ball bearing directly affects the dynamic characteristics of machinery. A modified quasistatic model of the ball bearing is established considering the influences of thermal deformation, centrifugal deformation, and elastohydrodynamic lubrication (EHL). Then, the film stiffness model considering spin motion is constructed. On this basis, the composite stiffness model of the ball bearing is proposed, and the effects of different factors on dynamic characteristic parameters are investigated. The results show that different factors have different effects on the dynamic parameters. With the increase in preload, the contact stiffness and composite stiffness increase. Considering EHL, the radial contact stiffness and composite stiffness increase while the axial and angular contact stiffness and composite stiffness decrease. Considering the thermal effect and centrifugal effect, the radial contact stiffness and composite stiffness increase while the axial and angular contact stiffness and composite stiffness decrease. The film stiffness and composite stiffness increase with the consideration of the spinning motion.

Modelling and Experimental Investigation of Hexagonal Nacre-Like Structure Stiffness

A highly ordered, hexagonal, nacre-like composite stiffness is investigated using experiments, simulations, and analytical models. Polystyrene and polyurethane are selected as materials for the manufactured specimens using laser cutting and hand lamination. A simulation geometry is made by digital microscope measurements of the specimens, and a simulation is conducted using material data based on component material characterization. Available analytical models are compared to the experimental results, and a more accurate model is derived specifically for highly ordered hexagonal tablets with relatively large in-plane gaps. The influence of hexagonal width, cut width, and interface thickness are analyzed using the hexagonal nacre-like composite stiffness model. The proposed analytical model converges within 1% with the simulation and experimental results.

Influence of Different Carbon-Based Fillers on Electrical and Mechanical Properties of a PC/ABS Blend

The present work examines the influence of different carbon-based fillers on the performance of electrically conductive polymer blend composites. More specifically, we examined and compared the effects of graphene (GR), carbon nanotubes (CNTs) and carbon black (CB) on a PC/ABS matrix by morphological investigation, electrical and physic-mechanical characterization. Electrical analyses showed volume resistivity decreased when the CNTs and CB content were increased, although the use of melt-mixed GR did not really influence this property. For the latter, solution blending was found to be more suitable to obtain better GR dispersion, and it obtained electrical percolation with a graphene content ranging from 0.5% to 1% by weight, depending on the solvent removal method that was applied. There was a gradual improvement in all of the composites’ dielectric properties, in terms of loss factor, with temperature and the concentration of the filler. As expected, the use of rigid fillers increased the composite stiffness, which is reflected in a continuous increment in the composites’ modulus of elasticity. The improvements in tensile strength and modulus were coupled with a reduction in impact strength, indicating a decrease in polymer toughness and flexibility. TEM micrographs allowed us to confirm previous results from studies on filler dispersion. According to this study and the comparison of the three carbon-based fillers, CNTs are the best filler choice in terms of electrical and mechanical performance.

The role of stiffness variation in switches and crossings: Comparison of vehicle–track interaction models with field measurements

The performance of switches and crossings compared with plain line is complicated by the presence of movable parts, changing rail geometry and non-uniformities in the composite and/or trackbed stiffness. These features lead to complex vehicle–track interactions and higher maintenance costs. The trackbed stiffness is the least well-controlled engineering property. A greater variability in trackbed stiffness leads to higher differential trackbed settlement and associated poorer track quality. At switches and crossings, changes in trackbed stiffness are exacerbated by changing rail properties which also contribute to changes in the overall composite track stiffness. This work focuses on the role of variations in stiffness on the performance of switches and crossings. Field measurements of bearer displacement were carried out using geophones at a switch and crossing equipped with under sleeper pads. The vehicle–switch and crossing interaction was modelled using a multi-body system and finite element method. The trackbed stiffness along the whole of the switch and crossing was inferred using the measurements of track deflections in an iterative back-calculation taking account of changing rail properties. It is shown that not including the variation in trackbed/composite stiffness leads to significant under/overestimates of the wheel–rail contact forces. Under sleeper pads are shown to reduce absolute maximum loads, but may increase the variation in deflection.

Analytical Modeling

The large number of available natural fibers emphasizes the use of a reliable, non-costly and easy to use, predictive tool with short computation time. In order to predict the ultimate strengths and Young's moduli of green composites, an analytical model known as the three Stages Homogenization Model (3SHM) is used. The model relies on three main parts: a geometrical model, a homogenization method and a strength model. Moreover, the last two models consist of four main parts: a micro-mechanical modeling for elastic properties and ultimate strengths for unidirectional (UD) composites, a homogenization method at meso and macro levels to determine the composite stiffness and stress-strain fields throughout the composite, two 3D failure criteria for the matrix and unidirectional composites and a damaged stiffness model. This model enables the prediction of the ultimate strengths and the 3D elastic properties; Young's and Shear moduli, in addition to the in plane and out plane tensile and shear strengths.

Mechanically triggered composite stiffness tuning through thermodynamic relaxation (ST3R)

Mechanically triggered relaxation of metastable liquid metal is used to autonomously alter the stiffness of a polymer composite. This approach to smart responsive materials exploits distribution in thermodynamic potential to tune the response rate.

A Model for the Mullins Effect in Multinetwork Elastomers

Double and triple network (TN) elastomers can be made by infusing monomers into a single network (SN) polymer, causing it to swell, and then polymerizing and cross-linking the monomers. The result is a double network (DN) elastomer in which one network is stretched and the other is in hydrostatic compression. TN systems are made by repeating the process starting with the DN material. The multinetwork (MN) elastomers exhibit a Mullins effect in which softening occurs upon a first cycle of loading, with the elastomer stiffness recovered above the previous maximum strain. The Mullins effect is attributed to rupture of the stretched network, eliminating the constraint on the compressed network, thereby motivating straining at the lower stiffness of the remaining material. A model for this process is developed, based on the previous work of Horgan et al. (2004, “A Theory of Stress Softening of Elastomers Based on Finite Chain Extensibility,” Proc. R. Soc. A, 460(2046), pp. 1737–1754). In the proposed model, a composite stiffness for the MN system is developed and a damage process introduced to degrade the contribution of the stretched network. The damage model is designed to account for the progressive elimination of chains that are most highly loaded in the stretched network, so that the undamaged stiffness is restored when the strain rises above levels previously experienced. The proposed model reproduces the behavior of the Mullins effect in the MN system.