CHAPTER 7

SHORT FIBER COMPOSITES

Department of Mechanical & Aerospace Engineering
MAE4315/AE5315/ME5348 Fall 2010
Chapter7- 2
References
1. Analysis and Performance of Fiber Composites
by B.D.Agarwal and L.J.Broutman
Published by John Wiley & Sons, Inc.
1990 (2
nd
edition)
2. Principles of Composite Material Mechanics
D.F.Gibson
Published by McGraw-Hill, Inc.
1994
Department of Mechanical & Aerospace Engineering
MAE4315/AE5315/ME5348 Fall 2010
Chapter7- 3
OUTLINE
7.1 Introduction
7.2 Theories of Stress Transfer
7.2.1 Fiber stress distribution
7.2.2 Critical fiber length
7.2.3 Average fiber stress
7.3 Strength of Short-Fiber Composites
7.4 Modulus of Short-Fiber Composites
7.5 Effects of Matrix Ductility
7.6 Fatigue Behavior
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Chapter7- 4
7.1 Introduction
The composites containing short fibers (or called
chopped fibers) as the reinforcement are called
short-fiber composites.
The short-fiber composites are often referred to as
chopped fiber reinforced composites or
discontinuous fiber-reinforced composites.
What is the short-fiber composites?
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Chapter7- 5
Why need short-fiber composites?
Low cost / high volume production
Short fibers can be easily mixed with the liquid matrix resin and
fiber/resin mixture can be injected or compression molded to
produce structural parts.
Ease of Fabricating Complex Parts
The complex structural components using continuous fiber
reinforced composites have difficulties in conforming to the desired
shape without being damaged or distorted from the desired
pattern.
Isotropic Behavior
Randomly oriented short fiber reinforcement gives isotropic
behavior of structural response, thus easy for analysis.
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Chapter7- 6
Examples of Short-Fiber Composites
Type Molding method
Fiber lengths
(cm)
Fiber orientation
Fiber-reinforced thermoplastics Injection molding <1.25
Random or dependent on
flow in mold
sheet-molding compound (polyester
resin matrix)
Compression molding or
sheet stamping
2.5-7.5
Random in compound but
dependent on flow in mold
Bulk-molding compound Compression molding <2.5
Random in compound but
dependent on flow in mold
Nonwoven-mat-reinforced
thermoplastic
Sheet stamping <7.5 Random
Nonwoven-mat-reinforced
thermoset
Contact molding or
laminating
<7.5 Random
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Chapter7- 7
Types of Discontinuous Fiber Reinforcement
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Chapter7- 8
Schematic Representation of Matrix Shear Deformation
7.2 Theories of Stress Transfer
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Chapter7- 9
7.2 Theories of Stress Transfer(Contd)
(Aligned Short Fibers)
For a good understanding of the behavior of short-fiber
composites, it is necessary to first understand the mechanism of
stress transfer.
Assumptions:
Fibers have circular cross-section
Fibers are uniformly distributed
Fibers and matrix are perfectly bonded
Stress transfer at the fiber ends by matrix shear
mechanism between fiber and matrix
No interaction between neighboring fibers
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Chapter7- 10
Relationship of Fiber Stress and Interfacial Shear
Force balanced
( ) 0
4 4
2 2
= +
i f f f f f f
dx d d d d t t o
t
o o
t
( )

= = = =
x
f i
f
f
f
i
f
dx
d d dx
d
0
0 at x 0 setting
4 4
o t o
t
o
(7-1)
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Chapter7- 11
Assumed Interfacial Stress/Strain Curve
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Chapter7- 12
Assuming that interfacial shear is constant, we have
The above equation indicates that the fiber stress is not
uniform along the length of the fiber. The stress, is
zero at the both ends of the fiber and is linearly dependent
on the length. Therefore, the stress reaches a maximum at
the mid-length of the fiber, i.e. at x=l
f
/2
f
o
7.2.1 Fiber Stress Distribution
f
f
i
f
l
d
t
o
2
max
=
Where l
f
= fiber length (7-2)
x
d
f
i
f
t
o
4
=
(Kelly-Tyson Model)
(7-2)
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Chapter7- 13
Effect of Fiber Length on Stress Distribution along Fiber
l
f
< l
c
l
f
= l
c
l
f
> l
c
f
o
y
t
x
t
1
1 1
E
E
c f
o
1
E
ult
f
o
x
2
c
l
2
c
l
2
c
l
2
c
l
ineffective length
effective length
ult
f
o = ultimate strength of the fiber
7.2.1 (contd)
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Chapter7- 14
m f c
c c c = = where c: composite, f: fiber, m: matrix
c
c
f
f
f
f
c
c
E
E
E E
o o
o
o
= =
(7-4)
c
c
f
i i
f
f
f
E
E
d
l
o
t t
o

|
|
.
|

\
|
= =
2
1
2
(7-5)
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Chapter7- 15
Solution:
c
c
f
i i
f
f
f
f
f
i f
E
E
d
l
d
l
o
t t
o
t o
|
|
.
|

\
|
= = =
2
1
2
2
max ,
max ,
Step 1: Determine
MPa 14
2
28
2
= = =
YS
i
o
t
i
t
Step 2: Compute
30.1GPa V E V E E
m m f f c
= + =
c
E
f
l Step 3: Compute
mm
d l
f f
174 . 0
70
1 . 30
70
14 2
1
=

|
.
|

\
|

=
Example:
A composite is fabricated of glass fiber (df=0.03mm) in an epoxy resin
matrix. All the fibers are aligned parallel to the direction of load application.
The fiber volume fraction is 40%. Assume that the matrix behaves as a
rigid-plastic material with a tensile yield strength of 28MPa and that
Ef=70GPa and Em=3.5GPa. Determine the load transfer length, lf for
composite stresses, oc=70Mpa.
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Chapter7- 16
7.2.2.Critical Fiber Length
The minimum fiber length required for the fiber stress to be
equal to the fiber ultimate strength at its mid-length is called
the critical fiber length.
For effective fiber reinforcement, l
f
>> l
c
For a given fiber, l
c
can be controlled by increasing/decreasing
may be increased by using coupling agent.
.
i
t
i
t
c f
ult
f f
l l = = at
max
o o
i
ult
f
f
c
c
f
i
ult
f f
f
i
f
d
l
l
d
l
d t
o
t
o
t
o
2
2 2
max
= = = (7-6)
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Chapter7- 17
Longitudinal Strength of Aligned Short-Fiber Composite vs. Fiber Length
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Chapter7- 18
7.2.3 Average Fiber Stress

=
f
l
f
f
f
dx
l
0
1
o o
=
max , f
o
f
l
f
l
f
o
c f
l l <
c f
l l =
c f
l l >
f f f f
l l o o =
max ,
2
1
max ,
2
1
f f
o o =
=
2
c
l
f
l
f
o
ult
f
o
2
c
l
c f
l l
Area equal
f
f
i
f
f
i
f f
l
d
l
d
= = =
t t
o o
2
2
1
2
1
max ,
(7-7)
i
f
c
ult
f f
d
l
t o o = =
2
1
(7-8)
( )
|
|
.
|

\
|
=
|
|
.
|

\
|
= = +
f
c
c
f
i
f
c
ult
f f f f c f f
ult
f
l
l
l
d l
l
l l l l
2
1
2
2
1
2
1 t
o o o o
(7-9)
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Chapter7- 19
7.3 Strength of Short-fiber Composite
7.3.1 Longitudinal Strength Model
(Aligned Short-Fiber Composites)
f
m
m f c
P P P + =
m m f f c c
A A A o o o + =
m m f f c
V V o o o + =
where V
f
=A
f
/A
c
= fiber volume fraction
V
m
=A
m
/A
c
= matrix volume fraction
For short-fiber composites,
m m f f c
V V o o o + = (7-10)
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Chapter7- 20
Longitudinal Stress of Uni-directional Lamina
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Chapter7- 21
Stress-Strain Curve for Hypothetical Composites
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Chapter7- 22
7.3.2 Effects of Fiber length on Longitudinal Strength
This implies that the fibers will not fracture
regardless of the magnitude of the applied stress.
Therefore, the composite will fail when the matrix
or interface fails. Hence, the composite ultimate
strength can be approximately given by
at fracture
m
ult
m f
f
f
i m
ult
m f f
ult
f
V V
d
l
V V o t o o o + = + =
max ,
2
1
(7-12)
Case 1: l
f
< l
c
max ,
2
1
f f
o o =
m m f f c
V V o o o + =
max ,
2
1
ult
f f
o o <
max ,
(7-11)
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Chapter7- 23
7.3.2 (Contd)
at fracture
m m f
f
c
i
ult
f
V V
d
l
ult
f
c
o t o + =
(7-14)
Case 2: l
f
= l
c
ult
f f
o o
2
1
=
m m f
ult
f c
V V o o o + =
2
1
(7-13)
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Chapter7- 24
7.3.2 (contd)
Case 3: l
f
> l
c
m m f
f
c
ult
f
ult
c
V V
l
l
ult
f
c
o o o +
|
|
.
|

\
|
=
2
1
at fracture
|
|
.
|

\
|
=
|
|
.
|

\
|
=
f
c
ult
f
f
c
f f
l
l
l
l
2
1
2
1
2
1
max ,
o o o
(7-15)
Case 4: l
f
>> l
c
(continuous fiber reinforced composites)
ult
f f
o o ~
at fracture
m m f
ult
f
ult
c
V V
ult
f
c
o o o + = (7-16)
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Chapter7- 25
In the above equations, we assume that the
fiber volume fraction is above a certain size so
that the matrix will not be able to support the
full load when all the fibers break and
composite failure will then take place.
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Chapter7- 26
Ultimate Strength of Uni-directional Composite vs.
Fiber Volume Fraction
7.3.3 Effect of Fiber volume Fraction
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Chapter7- 27
Minimum Fiber Volume Fraction, V
f,min
V
f,min
is defined as the minimum fiber volume fraction
that ensures fiber-controlled composite failure.
If V
f
<V
f,min
, the matrix will be able to support the entire
composite load when all the fibers break. Further, the
matrix will be able to take additional load with
increasing strain. Hence, we can assume that the failure
strength of the composite is equal to the ultimate
strength of the matrix.
( )
f
ult
m f
ult
f
ult
c
V V + = 1 o o o
( )
min , min ,
1
f m f
ult
f
ult
c
V V
ult
f
+ =
c
o o o
ult
m m
ult
f
m
ult
m
f
ult
f
ult
f
V
o o o
o o
c
c
+

=
min ,

}
(7-17)
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Chapter7- 28
Critical Fiber Volume Fraction, V
f,cr
V
f,cr
is defined as the minimum fiber volume fraction
that will allow the composite to strengthen its strength to
the matrix unreinforced strength.
ult
f
ult
f
m
ult
f
m
ult
m
cr f
V
c
c
o o
o o

=
,
( )
ult
m
cr f m cr f
ult
f
ult
c
V V
ult
f
o
o o o
c
=
+ =
, ,
1
(7-18)
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Chapter7- 29
For short-fiber composites,
ult
f
o
is replaced by
f
o
It is concluded that, for identical properties of fiber and
matrix materials, short-fiber composites require higher
values of V
f,min
and V
f,cr
than do the continuous-fiber-
reinforced composites.
ult
m m f
m
ult
m
short
f
ult
f
ult
f
V
o o o
o o
c
c
+

=
min ,
ult
f
ult
f
m f
m
ult
m
short
cr f
V
c
c
o o
o o

=
,
(7-19)
since
ult
f f
o o <
then
min , min , f
short
f
V V >
and
cr f
short
cr f
V V
, ,
> (7-20)
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Chapter7- 30
Halpin-Tsai Equation
C is property of composite
is a parameter depending on the fiber geometry,
packing geometry and loading direction.
c
C
m
is matrix property of composite
C can be modulus, thermal conductivity, etc.
7.4 Modulus of Short Fiber Composites
f
f
m
V
V
C
C
n
cn

+
=
1
1
where
c
n
+

=
m f
m f
C C
C C
/
1 /
(7-21)
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Chapter7- 31
7.4.1 Modulus for for Aligned Short-Fiber Composites
Longitudinal modulus
f L
f L L
m
L
V
V
E
E
n
n c

+
=
1
1
where
L m f
m f
L
E E
E E
c
n
+

=
/
1 /
, 2
f
f
L
d
l
= c
(7-22)
Transverse modulus
f T
f T T
m
T
V
V
E
E
n
n c

+
=
1
1
where
2 =
L
c
(independent of fiber length
and its diameter)
T m f
m f
T
E E
E E
c
n
+

=
/
1 /
(7-23)
Shear modulus
f G
f G G
m
LT
V
V
G
G
n
n c

+
=
1
1
where
G m f
m f
G
G G
G G
c
n
+

=
/
1 /
1 =
G
c
(7-24)
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Chapter7- 32
Comparison Between Predictions and Experimental Results
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Chapter7- 33
Variation of Modulus (E
L
/E
m
) with Fiber Aspect Ratio (l
f
/d
f
)
(Aligned Short-Fiber Composites)
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Chapter7- 34
7.4.2 Modulus For Randomly Oriented Short-fiber Composites
The randomly oriented short-fiber composites can be
considered as an isotropic material . The following
equations are often used to predict the modulus:
where E
L
and E
T
are the moduli for the aligned short-
fiber composite.
;
8
5
8
3
T L random
E E E + =
T L random
E E G
4
1
8
1
+ =
(7-25)
( )
random
random
random
E
G
v +
=
1 2
or 1
2
=
random
random
random
G
E
v
(7-26)
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Chapter7- 35
Example:
A glass-fiber-reinforced nylon with V
f
=0.2 is injection-molded to
produce a random fiber orientation. The fiber length is 3.2mm and
the fiber diameter, 10um. Calculate the elastic modulus, shear
modulus, and Poissons ratio of the randomly oriented fiberous
composite. (E
f
=72.4GPa, E
m
=2.76GPa)
GPa E
V
V
E
E
L
f L
f L L
m
L
26 . 16
1
1
=

+
=
n
n c
03787 . 0
/
1 /
=
+

=
L m f
m f
L
E E
E E
c
n
640
01 . 0
2 . 3
2 2
=
= =
f
f
L
d
l
c
Step 1: Compute E
L
; 53 . 4
1
1
GPa E
V
V
E
E
T
f T
f T T
m
T
=

+
=
n
n c
89 . 0
/
1 /
=
+

=
T m f
m f
T
E E
E E
c
n
; 2 =
L
c
Step 2: Compute
E
T
Step 3: Compute E
ran
& G
ran
; 93 . 8
8
5
8
3
GPa E E E
T L ran
= + = ; 17 . 3 GPa G
ran
= 41 . 0 =
ran
v
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Chapter7- 36
7.4.2 (contd)
2D and 2D Random Orientations of Fibers
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Chapter7- 37
7.5 Effect of Matrix Ductility
Ductile and Brittle Matrices in Short-Fiber Composites
Tensile stress-strain Curves
Tensile strength vs. fiber volume fraction
Notched impact strength vs. fiber volume fraction
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Chapter7- 38
Properties of Different Blends of Matrix Materials
DER 334(brittle resin); DER 736 (Ductile resin)
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Chapter7- 39
Tensile Stress-Strain Curve of Glass-Fiber Mat Reinforced Composites
Composite C shows lower strength
and modulus but a slightly larger
strain to failure compared to
Composites A and B.
The reason for the low elongation
to failure of Composite C
compared with its matrix is that
the matrix in the composite is
confined by fibers and cannot
deformed.
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Chapter7- 40
Tensile Strength vs. Fiber Volume Fraction Glass-Fiber Mat Reinforced
Composites
The max. tensile strength for
composite A occurs at V
f
=50%,
beyond which there is a slight
decrease in strength because of
fabrication difficulties in
obtaining a good quality of
composite at a high V
f
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Chapter7- 41
Notched Impact Strength vs. V
f
Glass-Fiber Mat Reinforced Composites
Matrix ductility has little
influence on the notched impact
strength of such composites.
Reasons:
Fibers limit the elongation
of the matrix in ductile
matrix composites
Blunting, branching and
arrest of matrix composite
result in increase of
toughness
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Chapter7- 42
7.6 Fatigue Behavior of short-fiber composites
General Observation
Compared to continuous-fiber reinforced
composites, short-fiber composites of all kinds
are much less resistant to fatigue damage
Fatigue damage in randomly oriented short-fiber
composites is initiated by debonding those fibers
that lie perpendicular to the loading direction
In aligned short-fiber composites, the fiber ends
and weak interfaces are often sites of fatigue
crack initiation
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Chapter7- 43
Fatigue Behavior Comparison between Several Reinforced Composites
A. Boron/ep laminate axial tension
cycling
B. Carbon/Polyester, V
f
=40% axial
tension cycling
C. as B; flexure cycling
D. gr/ep, tension cycling
E. gr/ep, compression cycling
F. Gl/polyester fabric laminate axial
tension/compression
G. Chopped glass mat/polyester
laminate, tension/compression
(randomly orientated fibers)
H. Dough-molding compound random
fiber orientation
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Chapter7- 44
S-N Curve of Glass/Polyester Chopped-Strand Mat
Zero mean stress
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Chapter7- 45
Fatigue Behavior of Random Glass-Reinforced Plastics
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Chapter7- 46
Effect of hole on Fatigue Strength of Glass/Polyester Chopped-Strand Mat
Composite