ICME 2023: ICME for Non-Metals: I
Program Organizers: Charles Ward, AFRL/RXM; Heather Murdoch, U.S. Army Research Laboratory
Monday 1:10 PM
May 22, 2023
Room: Caribbean VI & VII
Location: Caribe Royale
Session Chair: George Spanos, TMS
1:10 PM Invited
Multiscale Modeling of Structure-property Relationships in Highly Filled Thermoplastic Composites: Karthik Rajan Venkatesan1; John Hana1; Samuel Owoeye2; Ajay Kadiyala2; Joseph Lawrence2; Ajay Krishnamurthy1; 1Eaton; 2University of Toledo
A synergistic multi-scale modeling framework that captures multi-filler interactions at the microstructural level is developed to establish the structure-property relationships of injection-molded thermoplastics with graphite and carbon fiber reinforcements. Representative volumetric elements (RVEs) of the material samples are generated based on known geometrical features extracted using raw images obtained from optical and electron microscopy. Geometrical parameters such as filler orientation and size distribution are calibrated using two baseline samples containing only graphite and carbon fiber fillers, respectively. These parameters are systematically correlated to the differences in viscosities of the molded samples. The calibrated parameters and modeling strategies are then used to generate the combined filler system microstructures to capture the synergistic effects of integrating graphite and carbon fiber. The predicted mechanical and thermal properties are verified and validated for various graphite and carbon fiber weight fractions. Future pathways to improve model prediction capabilities and accuracies are presented.
1:40 PM
Multi-scale Modeling of Composites Manufacturing Processes: Huidi Ji1; Ross McLendon1; Reinier Akkermans1; 1Dassault Systemes
In this work we present the simulation of various composite manufacturing processes using multi-scale modeling techniques in Abaqus to predict how these processes impact the final composite component. Plastic injection molding is simulated to predict fiber dispersion which is imported into Abaqus FE analyses to predict warpage and performance under service loads. Additionally, compression molding is simulated to predict fiber reorientation due to large deformations during the compression process. These forming results including fiber orientation and residual stresses are mapped into subsequent FE analyses for warpage analyses. Finally, the cure process is simulated at small length scales to predict both the homogeneous composite cure response and evaluate how the residual stress field in the composite microstructure interacts with mechanically-induced stresses.
2:00 PM
Integrated Framework for Cure-informed Progressive Damage and Failure Analysis of Composite Structures: Minh Hoang Nguyen1; Royan Dmello1; Anthony Waas1; 1University of Michigan
We present a finite element (FE) - based framework to perform integrated cure and progressive failure analyses of fiber-reinforced polymers. This framework goes beyond the unit cell and is applicable to laminate scales with various layups, geometries and loading cases. Cure residual stresses are calculated using a coupled chemo-thermo-mechanical analysis, where a data-driven CHILE (cure-hardening/ instantaneous linear elastic) constitutive model is used to capture the evolution of the matrix properties (Nguyen, Dmello and Waas, Archive of Applied Mechanics, 2022). After the residual stresses are calculated, a progressive failure analysis step is performed based on the semi-discrete modeling technique (Nguyen and Waas, Composites Part C, 2020). It comprises a smart meshing strategy, a failure separation, a probabilistic modeling approach, and a mesh-objective constitutive model. The enhanced semi-discrete damage model (eSD2M) can capture multiple failure modes and their interactions as well as predict failure loads with reasonable accuracy.
2:20 PM
Simulating the Microstructure to Property Relationships with Multiscale Recursive Micromechanics: Evan Pineda1; Joshua Kemppainen2; Jamal Husseini3; Brett Bednarcyk1; William Pisani4; Gregory Odegard2; Scott Stapleton3; 1NASA Glenn Research Center; 2Michigan Technological University; 3University of Massachusetts, Lowell; 4U.S. Army Engineer Research and Development Center
Thermoplastic materials, including polyether ether ketone (PEEK) and polyether ketone ketone (PEKK) are high-performance semi-crystalline polymers ideal for aerospace applications because of their excellent properties, toughness, resistance to aging, manufacturability and “tailorability.” Understanding the linkages between the microstructure of the material and its properties facilitate designing of the material itself. A multiscale recursive micromechanics (MsRM) model has been developed and implemented in the NASA Multiscale Analysis Tool (NASMAT). The microstructure of the thermoplastic is modeled using MsRM over three integrated scales (spherulite, lamellar stacks, granular crystal blocks). Inputs for the base constituents are obtained from molecular dynamics calculations. With this computational tool, the effects of microstructure to property relationships are simulated through parametric studies on crystallinity, spherulite packing, and morphology of the microstructure.
2:40 PM
Design of 3D-printed Nanocomposite Shields for Efficient EMI Shielding via Finite Element Modelling: Frederik Van Loock1; Patrick Anderson1; Ruth Cardinaels1; 1TU Eindhoven
Electronic devices emit electromagnetic (EM) waves, which may interfere with neighboring electronic components, a phenomenon known as electromagnetic interference (EMI). Conventional metallic shields exhibit high shielding effectiveness values. Yet, most of the power is reflected, resulting in secondary EM pollution. Instead, one can make use of polymer nanocomposite shields which are able to partially absorb the incident power. The challenge is to produce polymer-based shields of high shielding effectiveness where most of the power is absorbed instead of reflected. In this work, we explore the use of 3D gradients in electromagnetic properties within a nanocomposite layer to fill this gap in material property space. An efficient 3D finite element model is constructed to predict the shielding performance as a function of EM property gradient and geometric design of the layer. After validation with experimental data for uniform nanocomposite layers, we use the model to identify optimal material design cases.
3:00 PM Break