Estimate the elastic modulus and strength

of composites with Basalt woven fiber reinforcement and thermal silica

geopolymer matrix by ANSYS software
Nhan Phan Thanh1, Thai Huynh Le Hong2
1
Technical University of Liberec, Faculty of Mechanical Engineering, Department of Applied Mechanics,
Liberec, Czech Republic. Tel. +420 773 06 18 35. Email: nhancohoc@yahoo.com
2
Technical University of Liberec, Faculty of Mechanical Engineering, Department of Vehicle and Engines,
Liberec, Czech Republic. Email: huynhlehongthai@yahoo.com
Abstract
The popular important properties of most composites with fiber reinforcement and geopolymer matrice are
elastic modulus (Young’s modulus) and flexural strength in bending experiment. However, only loads and
deflections of material specimens are measured directly from bending experiment while stresses and strains of
material are derived indirectly from ASTM standard formulae. Then elastic modulus and flexural strength will
be calculated from the stress-strain curve of material. These formulas are considered to approximate.
Therefore, estimating the elastic modulus and flexural strength of Basalt woven fiber reinforced composites
with thermal silica geopolymer matrice by other independent methods like ANSYS software is necessary. The
results of this study seem to promise in view of evaluating properly mechanical properties of composite
material with Basalt woven fiber reinforcement and thermal silica geopolymer matrix (CFCC).

Keywords: CFCC, estimate, elastic modulus, flexural strength

1. INTRODUCTION
Basalt woven fiber-reinforced composite based on Thermal Silica Geopolymer is the
most interested material currently. This well-known material exhibit excellent features such
as: lightweight and high strength (specified strength), having ideal fire resistance and
nontoxic fumes and smokes, and resists all organic solvents. The cost of material is rather
low compared with other conventional composites [7]. The most important mechanical
properties of composite materials are elastic modulus and flexural strength in bending
experiment. However, only loads and deflections of material specimens are measured
directly from bending experiment and stresses and strains of material are derived indirectly
from ASTM standard formulae [5]. Then elastic modulus and flexural strength will be
calculated from the stress-strain curve of material. The formulas of loads related to stresses
and of deflections related with strains are approximated in linearity while the behavior of
material is nonlinear. Therefore, estimating an elastic modulus and flexural strength of Basalt
woven fiber reinforced composites with thermal silica geopolymer matrice by another
independent method like ANSYS software is a necessary work.
In this paper, the elastic modulus and strength in flexure will be measured in laboratories,
and then they also will be estimated by ANSYS software and by theory of composite
material mechanics.

2. MATERIALS AND EXPERIMENTS

2.1 Materials
Geopolymer resin was prepared according to the simplified procedure described in the
patent [8]. The formulation of geopolymer matrix used here abbreviated as ‘M2’, consisted
of thermal silica, potassium hydroxide solution or potassium water glass, alkali phosphate
addition and further minor admixtures for improving application features. The flexural
properties and of pure resin are showing Table 1.
The reinforcement used in composite discussed in this paper is Basalt woven fabric that
came from Basalt BCF13 - 2520tex - KV12 Int. and showed in Fig. 1. The mechanical
 properties of the reinforcement are in Table 2. Density of Basalt BCF13 woven fabric is
ρw = 200g/m2

2.2 Preparation of composite specimens

Woven fabrics were impregnated (“wet out”) with geopolymeric resin, stacked and
compressed by a roller, Fig. 2. Number of layers is chosen so that to obtain plate thickness of
4mm is 19 layers in approximation. The plate was cured under a technique called “vacuum
bagging” (-1atm) firstly, at room temperature for 1 hour and then under a technique called
“hot press vacuum bagging” at -1atm at chosen 80oC temperature in an oven for two hours.
After that, the composite plate was cut into 14 specimens in bar shape (Fig. 3.) and the
specimens were measured lengths, widths, thickness and weighed. These values of lengths,
widths, thickness and mass of samples will be used to calculate the average length, width,
thickness and the volume fraction of fiber and matrix from series of samples. Finally, the
samples were kept in room condition for 15 days before to do experiment.

Table 1. Flexural properties of the pure geopolymer matrix at different spans

Span of the beam

Matrix 40 mm 80 mm 120 mm
σf E e σf E e σf E e
[MPa] [GPa] [%] [MPa] [GPa] [%] [MPa] [GPa] [%]
M2 16.6 9.0 0.19 17.6 18.8 0.35 - - -
Where σf , E, ε are flexural strength, elastic modulus and failure strain, respectively.

Table 2. Main properties of selected fibers from producers or suppliers

Fiber tex d0 r σ E e Producer/Dealer

[g/km] [µm] [Mg.m-3] [MPa] [GPa] [%]

Basalt
BCF13 - 2600~ Basfiber®, Kamenny Vek,
2520 13 2.67 85-90 x
2520tex - 2800 Russia, www.basfiber.com
KV12 Int
where tex - Nominal linear density
do - Average diameter of fiber filament
σ - Tensile strength
E - Tensile module
e - Failure strain

2.3 Mechanical testing setup

Series of samples were prepared and tested for flexural properties under laboratory
conditions by three-points bending mode in accordance with ASTM C1341-06 [5] by a
system of a linear hydraulic engine Inova AG 25-100 with displacement sensor integrated in
the hydraulic engine and force sensor GTM K-S 500N No. 51221. All were controlled and
measured by the system Inova CU33 M03 with Software Test control 1.2 for engine control
and Software Dewsoft 7.02 for data acquisition (Fig. 4.). The rate of cross-head motion is
2.4mm/s at span 240 mm (outer support span-to-depth ratio is about 60 to 1)
Fig. 1. Basalt woven fabric

Fig. 2. Plate geopolymer composite making

Fig. 3. Composite specimens Fig. 4. Testing machine

2.4 Results
Data of force-deflection relation, where Force (P) – N ; Deflection (D) – mm, will be
gained from the testing system. Stress-strain data of material sample are calculated from
equation (in accordance of ASTM C1341-06):
3PL
sf = (1)
2bh 2
where:
σf is the flexural stress, in megapascals (MPa);
P is the loads, in newtons (N);
L is the span, in millimeters (mm);
h is the thickness of the specimen, in millimeters (mm);
b is the width of the specimen, in millimeters (mm)

6 Dh
ef = (2)
L2
where:
εf is the flexural strain, (%);
D is the deflection, in millimeters (mm);
 The values of limit-proportional stresses (σp) and strains (εp), elastic moduli (E), flexural
strengths (σu) and strains (εu) at flexural strengths from the stress-strain curves of samples,
Fig. 5a.
where:
3P L 6D h
s u = max2 ; e u = 2m (3)
2bh L
Dm corresponding to Pmax
3P L 6D h
s p = p 2 ; e p = 2p (4)
2bh L

Dp corresponding to limit-proportional force Pp

sp
E= = tan a (5)
ep
In the case of e o ¹ 0 , Fig 5b, quantities εp, εu are calculated by formulas:
e p = e *p - e o , e u = e u* - e o (6)

s s
su su

sp sp
a e a e
ep eu eo e* e*
p u

Fig. 5a. Curve of stress-strain in bending Fig. 5b. Curve of stress-strain in bending
in the case of e o ¹ 0

Eventually, the average values of limit-proportional stress (σp) and strain (εp), elastic moduli
(E), flexural strengths (σu) and strains (εu) are determined.
sp = 23.16 ± 2.28(MPa) ; e p = 8.055.10-4 ± 1.909.10-5 ; E = 28.77 ± 2.97 (GPa) ;
su = 76.60 ± 5.29 (MPa) ; e u = 4.471.10 -3 ± 4.125.10 -4

3. SIMULATE COMPOSITE MATERIAL MECHANICAL PROPERTIES BY

ANSYS
3.1 Simulation based on nonlinear homogenization of mechanical responses of textile
reinforced composite in ANSYS.
It could be to simulate a composite material sample based on homogenization of
composite material. Therefore, with a purpose of comparing results, problem setup is to
model a beam that has homogeneous and isotropic material and dimension equal the average
length, width, thickness of the sample series and lies on two supports and is subjected loads.
The average dimension of the sample series is l = 275mm ; b = 14mm ; h = 4.4mm,
where l , b, h are length, width, thickness, respectively. Mechanical properties of composite
are selected from relation of average stresses and average strains obtained from experiment.
Stress-strain data of 22 points are shown in Fig. 6. We must also determine the loads, which
equal to average of loads in individual test, corresponding to points on the average stress-
strain curve from experiment (Table 3).

Procedure of programming for ANSYS can be done the following:

- Input of the specimen geometry with the averaged value of length, thickness of a
specimen (l = 275mm ; h = 4.4mm).
- Input of the material properties of a specimen:
· Material is looked like nonlinear.
· Use MULTILINEAR ISOTROPIC command to input stress-strain data
obtained from the average stress-strain curve (Table 3).
- Select the element type like plane stress through thickness.
- Input of the element thickness equal the specimen width (b = 14mm)
- Sizing of the elements
- Meshing
- Input of boundary conditions (constrains, loads).
- Input of every load value from Table 3 and then take solution and postprocessing
- Obtain maximum stresses and maximum strains corresponding to each load (Table
3)
- Redraw the stress-strain curve from stress-strain data calculated by ANSYS (Fig. 7.).
- Obtain the limit-proportional stresses (σp) and strains (εp), elastic moduli (E), flexural
strengths (σu) and strains (εu) at flexural strengths from the stress-strain curves
calculated by ANSYS, Fig 7.

Results:
sp = 23(MPa) ; e p = 8.0.10-4 ; E = 28.75 (GPa) ; su = 65.6 (MPa) ; e u = 3.1.10-3

The curve of stress - strain by ANSYS (based on

The average stress - strain curve from
nonlinear homogenised simulation)
experiment

100 80
80 60
Stress [MPa]

Stress [MPa]

60
40
40
20 20

0 0
0 0.001 0.002 0.003 0.004 0.005 0 0.001 0.002 0.003 0.004

Strain Strain

Fig. 6. The average stress-strain curve from Fig. 7. The stress-strain curve from ANSYS
experiment

3.2 Simulation of using linear layered elements of textile reinforced composite.

We can use layered solid element type (SOLID46) having 37 layers (including 19 fiber
layers and 18 matrix layers) and use two material properties of fiber and matrix to simulate
specimen with the averaged value of length, thickness of a specimen in another way. Thus,
stress and strain values of a specimen under loads from Table 3 will be calculated and listed
 also in Table 3. The stress-strain graph of composite material based on linear layered
modeling is showing in Fig. 8.

Results:
sp = 35.8(MPa) ; e p = 3.97.10-4 ; E = 90.18(GPa) ; su = 120 (MPa) ; e u = 1.333.10 -3

The stress-strain curve by ANSYS (based on

linear layered simulation)

150
Stress [MPa]

100
50
0
0 0,0005 0,001 0,0015

Strain

Fig. 8 The stress-strain curve by ANSYS based on linear layered simulation.

Stress distributions of a specimen under maximum load in nonlinear homogenized

simulation and in linear layered simulation are shown in fig. 9. , fig. 10.

Fig. 9. Stress distribution of a specimen under Fig. 10. Stress distribution of specimen under
maximum load in nonlinear homogenized maximum load in linear layered simulation
simulation

3.3 Determine the elastic modulus and flexural strength of composite in mechanical theory
In order to establish formulas simply to specify elastic modulus and flexural strength of
composite in mechanical theory, there should be set up some hypotheses relative to a beam
of a real composite material.
- Only the longitudinal fibers of specimens are subjected under flexural loads while the
transverse fibers of them are not.
 - The individual yarn sub-systems in woven fabric are assumed not to interact with
each other.
- Volume fraction of fibers in longitudinal and transverse directions are equivalent.

Calling E, Ef , Em are elastic moduli of the composite, fiber, and geopolymer matrix
respectively and Vf is the fiber volume fraction, hence the elastic modulus of composite can
be determined by a simple formula:
Vf
E = Ef + Em (1 - V f ) (7)
2
where Ef = 90 GPa , Em = 18,8 GPa (Table 1, 2)
Vf = 0.32 (is calculated on average of the fiber volume fractions of sample series)

A result E = 27.184 (GPa)

Table 3: Values of loads, stresses, strains of 22 points chosen from the averaged stress-
strain curve. Values of stresses, strains calculated by ANSYS in homogenized simulation and
layered simulation.
Loads from Stresses (MPa) Strains
experiment
P - (N) from from ANSYS from from from from
experiment in ANSYS in experiment ANSYS in ANSYS in
homogenized layered homogenized layered
simulation simulation simulation simulation
0 0 0 0 0 0 0
17.4 23.2 23 35.8 0.000805508 0.000800 0.000397
20.8 27.5 25.1 42.8 0.000988357 0.000883 0.000475
23.8 31.5 28.2 49.0 0.001171206 0.001022 0.000544
26.7 35.5 31.4 54.9 0.001354055 0.001166 0.000610
29.5 39.7 34.5 60.7 0.001536903 0.001307 0.000674
32.4 43.3 37.8 66.7 0.001719752 0.001455 0.000741
34.9 46.7 40.7 71.8 0.001902601 0.001590 0.000798
37.2 49.7 43.3 76.5 0.002085450 0.001719 0.000850
39.5 52.8 45.8 81.3 0.002268299 0.001853 0.000903
41.9 56.2 48.2 86.2 0.002451148 0.001997 0.000958
44.0 59.1 50.4 90.5 0.002633997 0.002127 0.001006
46.2 61.7 52.8 95.1 0.002816845 0.002266 0.001056
48.2 64.3 55.0 99.2 0.002999694 0.002388 0.001102
50.0 66.6 57.0 103.0 0.003182543 0.002501 0.001143
51.9 68.9 59.0 107.0 0.003365392 0.002628 0.001186
53.3 70.7 60.4 110.0 0.003548241 0.002729 0.001218
54.6 72.2 61.8 112.0 0.003731090 0.002824 0.001248
55.7 73.5 63.0 115.0 0.003913938 0.002905 0.001273
56.7 74.8 64.0 117.0 0.004096787 0.002978 0.001296
57.7 75.9 65.0 119.0 0.004279636 0.003054 0.001319
58.3 76.6 65.6 120.0 0.004471427 0.003100 0.001333

The mechanical characterization in a flexural beam is considered as the state of

complex stress. Several failure modes can occur such as fiber breakage in tension, fiber
buckling and delamination in compression. On the other hand, interlaminar shear is usually a
limiting design property for composite. When the transverse shear load experienced by a
laminated composite exceeds the interlaminar shear strength, a delamination failure will
occur between the layers of reinforcing fiber [2]. So it is hard to exist a theoretical formula to
calculate a totally flexural strength of a composite beam.

4. DISCUSSION AND CONCLUSION

Plot all the stress-strain curves from experiment and modeling by ANSYS together on a
coordinate system (Fig. 11.), it can be showing out some assesses from the above results:
- The stress-strain behaviors of composite material from experiment and nonlinear
homogenized simulation are very similar. This means that elastic moduli calculated from two
methods equal exactly. If comparing the results with the value of elastic modulus calculated
from theories, the difference of them is slight. However, flexural strength values of
composite material differ significantly. The limit of composite bending determined by
nonlinear homogenized simulation is lower compared to by experiment. This absolute
difference approximates to 11 MPa (reaches to 14.4% compared with the experiment flexural
stress limit). There can be explained all these assesses in the following.

According to mechanics of linear homogenized materials, stress and strain arose in a

bending beam are at (1), (2). This leads:
s L3 P 4 Ebh3
E= = . Þ P = .D = E ' .D (7)
e 4bh D 3
L3

4Ebh3
where E' = = constant (8)
L3
It means that relation of loads and deflections is linear in flexural beam if we use two
formulas of (1), (2) to determine stresses and strains. However, loads depend on deflections
in another rule from experiment. The load-deflection graph gained in laboratories can be
divided into two parts: linear part and nonlinear part. Comparing two graphs we will
recognize some remarkable factors (see fig.12.)

Pmax1
1
Pmax2
2
Pp1=Pp2

Fig. 12. Two load-deflection graphs

1-Curve of load and deflection from mechanics of linear homogenised materials
2-Curve of load and deflection from experiment

Firstly, the linear parts of two graphs coincide with each other so the elastic moduli
calculated from experiment and from nonlinear homogenized simulation must be the same.
Secondly, the maximum load measured in laboratories is lower than the maximum load
calculated from using two formulas of (1), (2). Therefore, the flexural strength calculated
from simulation based on nonlinear homogenized materials must be also lower than from
using two linear formulas of (1), (2).

- The elastic modulus and the flexural strength of composite determined by linear layered
simulation are too large. The causes are explained that the bonding between from woven
layers and geopolymer matrice are considered perfect bonding when modeling in ANSYS,
but the delamination occurs in doing experiment. This means that the real bonding between
from woven layers and geopolymer matrice is not well under the same loads, Fig. 13.

Delamination

Fig. 13. Failure mode

Flexural strength by linear layered simulation

Flexural strength by experiment

11 MPa Flexural strength by nonlinear homogenised simulation

Fig. 11. The stress-strain curves from experiment and modeling by ANSYS.

In summary, the elastic modulus in bending mode of composite material measured from
experiment is believable. Nevertheless, the flexural strength of composite material from
experiment is not satisfied and should be estimated by another independent method like
simulation based on nonlinear homogenization of material in ANSYS.

5. ACKNOWLEDGEMENTS
This work was supported by Ministry of Industry and Trade of Czech Republic under the
project #FT-TA4/068 and by Ministry of Education and Youth of Czech Republic under the
project MSMT 4674788501.

References:

[1]. Autar K.Kaw. Mechanics of material composite.2006, p.205-p.206

[2]. Salvatore Carmisciano. Basalt woven fiber reinforced vinylester composites: Flexural
and electrical properties, 2010, Elsevier journal.
[3]. Erdogan Madenci, Ibrahim Guven. The finite element method and applications in
engineering using ANSYS, 2006.
[4]. T.Stolarski, Y.Nakasone,S.Yoshimoto. Engineering analysis with ANSYS software,
2006.
[5]. ASTM C1341 – 06. Standard test method for flexural properties of continuous fiber-
reinforced advanced ceramic composites
[6]. ANYS release 10.0 Documentation for ansys. VM144, VM144 Input listing
[7]. Davidovits,J., Geopolymer Chemistry & Applications.2008, France: Institute
Geopolymer.587.
[8]. Mazany Anthony M.,R.J.W., Cartwrigth Craig L., Inorganic matrix compositions,
composites and process of making the same, U.S. Patent 6,899,837 , 2005.