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A composite material, such as fibreglass, consists of two distinct materials, a fibre (glass) and a binder or matrix (polyester) each with its own mechanical properties such as stiffness and strength. When the two materials are combined to make a composite, the mechanical properties depend not just on those of the two materials being mixed, but on the relative amount of each material - we use the term volume fraction to describe the relative volume occupied by the fibre or reinforcing material the shape and size of the reinforcement and its orientation with respect to the loads that are to be applied to the composite. Let's take the simplest of all composite materials, one made up from identical continuous fibres which are all aligned in the same direction and are to be subject only to loads applied parallel to the axis of the fibre. There are two properties that are of interest, the stiffness (Elastic Modulus) and the strength (Tensile Strength).

If the composite material is to stay in equilibrium then the force we apply to the composite as a whole, F, must be balanced by an equal and opposite force in the fibre, Ff and the matrix Fm.

When considering 'Strength of Materials' problems we usually work in terms of stress () (force per unit area) rather than force itself. So the force on the fibres is simply the stress on the fibres, f, multiplied by the cross-sectional area of the fibres lying perpendicular to the stress. The cross sectional area of the composite occupied by the fibres is just f, the volume fraction of the fibres multiplied by the cross-sectional area of the composite itself - we'll call that "A" - i.e. f.A. Similarly the force on the matrix is just the stress in the matrix multiplied the cross-sectional area of the matrix in the composite, i.e. (1-f).A . Since the cross-sectional area of the composite itself, A, is in each term on both sides of the equation we can cancel it out. So the stress in the composite is just the sum of the stresses in the fibre and the matrix multiplied by their relative cross-sectional areas.

The stress in the fibre and the stress in the matrix are not the same. Now the tricky bit! We can now use Hooke's Law, which states that the stress (or Force) experienced by a material is proportional to the strain (or deflection). This applies as long as the stresses are low (below the elastic limit - we'll come to that soon) and the material in question is linear elastic - which is true for metals, ceramics, graphite and many polymers but not so for elastomers (rubbers).

where E is the elastic modulus; the bigger this number the stiffer the material. For compatibility, the strain, , must be the same

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Mechanics of Composites - 1

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in both the fibres and the matrix otherwise holes would appear in the ends of the composite as we stretched it. This is known as the ISOSTRAIN RULE.

Since the fibre and matrix often have quite different elastic moduli then the stress in each must be different - in fact the stress is higher in the material with the higher elastic modulus (usually the fibre). In fibreglass, the elastic modulus of the glass (~75GPa) is much greater than that of the polyester matrix (~5GPa) so as the volume fraction of fibres is increased, the elastic modulus of the composite (measured parallel to the fibres) increases linearly.

Try selecting different types of polymer matrices, or different types of fibres and see how the different elastic properties change as you increase the volume fraction of fibres. The greyed areas to the right of the graph represent fibre contents which are either difficult to acheive in practice (light grey) or just plain impossible (dark grey). Click the button to display a particular elastic modulus (all units are GPa)

In practice it is very difficult to get more than 60% by volume of fibres which puts a practical limit on the maximum stiffness of the composite of 0.6xEf. While the rule of mixtures has proved adequate for tensile modulus (E) in the axial direction, the isostrain rule of mixtures does not work for either the shear (G) or bulk (k) moduli. Instead, these are dependent on the phase morphology. An example of shear modulus (G) and bulk modulus (k) dependencies for an assemblage of cylindrical fibres is shown below.

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If we were to look down on the top of the composite or along the axis of the fibres and apply a load perpendicular to the fibre axis then the composite would respond in a very different way.

In a fibrous composite with the applied stress aligned perpendicular to the fibres, the stress is transferred to the fibres through the fibre matrix interface and both the fibre and the matrix experience the same stress If the matrix and fibre have different elastic properties then each will experience a different strain and the strain in the composite will be the volume average of the strain in each material. Since the stress is the same in each phase this is known as the ISOSTRESS rule of mixtures. If a force is applied perpendicular to the fibres then the fibres and matrix will stretch in the same direction. The total deflection (d) is just the sum of the deflections in the fibre (df) and the matrix (dm).

Again, we can use Hooke's law to introduce the elastic modulus and since the stress is the same in both the matrix and fibre we can get the elastic modulus perpendicular to the fibres

Note that the stiffness of the composite, measured perpendicular to the fibres increases much more slowly than stiffness measured parallel to the fibres as the volume fraction of fibres is increased. Since the properties of the composite are different in different directions, the composite is anisotropic. Back to Calculator. See also Calculation of Shear modulus and Poissons ratio in aligned fibre composites using the halpi-Tsai equations.

Woven Fibres

The majority of structures made from composites, including sailboards, are made from woven cloth rather than the simple uniaxial fibres described above. As anyone who has pulled a piece of fibreglass cloth knows, it's very difficult to stretch (i.e. the cloth is stiff) when pulled parallel to either the warp or weft fibres (0 and 90), but easily stretches and distorts when pulled at 45 to either fibre axis. A rigorous analysis of the stiffness of a composite made from a simple woven cloth such as that shown below, is much more complex than the two situations which I have just described and will be carried out in a later section. However, a simple approximation of the properties is as follows. For a simple plain woven (2-P) cloth it is safe to assume that half of the fibres are in the warp (0) orientation and the other half are in the weft (90) direction. The stiffness in each of these directions is then simply calculated using the ISOSTRAIN rule of mixtures but assuming that the volume fraction of fibres, f, is only half the total fibre content. The stiffness at 45 to the fibres can be assumed to be just that of the matrix itself.

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8/12/2004

Mechanics of Composites - 1

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From the picture above you can see that each bundle of fibres, called a 'tow', consists of 100's of individual fibres each of which is about 10m in diameter. Download the MathCad Examples.

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8/12/2004

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