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Multi-scale finite element simulation of needle-punched quartz fiber reinforced composites

  • Weijing Niu EMAIL logo , Xiaopeng Yan , Haolin Shi and Zhangxin Guo
Published/Copyright: November 15, 2024
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Science and Engineering of Composite Materials
From the journal Science and Engineering of Composite Materials Volume 31 Issue 1

Abstract

To investigate the effects of different needling parameters on the mechanical properties of quartz needled felts and their composites, this paper proposes a multi-scale modeling approach to simulate and calculate the mechanical properties of needled quartz fiber-reinforced composites. Firstly, based on the characteristics of needle-punching technology, the morphology of needle-punched composites was analyzed at a microscopic scale, and the quartz fiber structure was divided into three typical representative regions. Then, a periodic single-cell model of needled composites was established. Meanwhile, this article also analyzes the influence of parameters such as needling density, needle type, and needling depth on the mechanical properties of needled composites.

Keywords: composites; mechanical properties; simulation; multi-scale; needle punched

1 Introduction

Needle-punch molding precast body has the advantages of strong structural design, uniform pore distribution, and easy dense molding, which improves the disadvantages of low interlayer strength of the paving structure, complicated process, and high cost [1,2,3]. This process improves the disadvantage of weak interlayer strength of 2D layup precast body and also solves the complexity of the 3D preparation precast body process, which can be widely used in aerospace, aviation, transportation, and other fields. Needle-punched reinforced composites body both 2D layup, 3D woven reinforcement advantages, precast body structure and performance can be designed, with its preparation of C/C material structure uniformity, high fiber volume content, excellent mechanical strength, can be molded into complex components, adapted to a variety of densification process.

Needling technique is the use of mechanical reinforcement, the fibers in the fiber network under the action of mechanical external forces through friction, hold together, entanglement reinforcement into non-woven fabrics, fibers produce flexible entanglement between the layers, making the layers and layers combined together, and the final product has a better dimensional stability, needling does not affect the original characteristics of the fibers, because of its z to the fibers of the process characteristics, so the needling of the composite material prefabricated body has a good interlaminar performance. Because of its z-fiber process characteristics, the needle-punched composite precast body has good interlaminar properties, which makes its application fields more widely. The mesh tires provide good interlaminar properties for the precast body, but the mechanical properties are poor, while the woven fabric provides mechanical properties for the precast body, so the mesh tires/woven fabrics are used to prepare the precast body alternately.

Quartz fiber has more excellent electrical wave-transparent properties and lower cost compared with other glass fibers, and its composite materials have lightweight, high strength, good thermal properties, and dielectric properties. Therefore, quartz fiber is widely used in missiles, radar, and other enclosures.

Han et al. [4] established a two-node 12-degree-of-freedom circular beam cell and a 6-degree-of-freedom extended spring cell to describe the fiber dimensional bundle deflection, thus establishing a discrete three-dimensional needle C/C composite. The discrete three-dimensional needle C/C composites finite element model was developed, and the tensile and compressive force behavior of the material was effectively predicted. Yu et al. [5] used micro-computerized tomography (CT) technique to obtain 3D needle C/C composite material. CT technique to obtain the internal structure image of 3D needled C/C composite material and reconstructed image to reflect the tensile and compressive force behavior, and reconstructed a numerical model to reflect the real internal structure of the material. The compressive and tensile mechanical properties of the composite material were effectively simulated.

The application environment of 3D needle-punched composite material is often closely related to temperature, friction, and electromagnetic waves due to its special structure and properties, which has attracted the attention and research of many scholars. Li et al. [6] investigated the failure mechanism and compression properties of C/C composite material and obtained nonlinear stress–strain curves. As the test temperature increased, the compressive properties of the material gradually decreased and the material underwent shear damage along a 45° angle. Shindo et al. [7] investigated the mechanical properties of polyester non-woven reinforced composite material at low temperatures. The results showed that the stiffness and strength of the material increased as the temperature decreased from room temperature to 77 K. The stiffness of the material exhibited isotropic properties and there was no significant difference in the failure mechanism of the material at different temperatures.

In this article, according to the microstructural characteristics of needle-punched composites, they are divided into three typical representative regions. The mechanical properties of each cell were calculated by applying periodic boundary conditions and brought into a single cell to obtain their mechanical properties. Studied the stress distribution patterns of representative volume elements (RVEs) and needle-punched fibers region. The influence of parameters such as needling density, needle type, and needling depth on the mechanical properties of needled composites was analyzed.

2 RVE stiffness calculation

This section divides the structure into three RVEs based on the microscopic characteristics of the morphology of needle-punched composites. Assign material parameters for needled fibers, plain fabric layers, and tufted fiber layers in RVEs. Apply periodic boundary conditions to RVEs, as detailed in Ref. [8]. By using the theory of computational homogenization [8,9], the mechanical performance parameters of RVEs and periodic unit cells can be obtained through calculation.

2.1 Material parameters

The material parameters in this article are taken from Ref. 10 and are shown in Table 1.

Table 1

Material properties [10]

Material Items Value
Plain fabric layer Young’s modulus E 11, E 22 13.49 GPa
Young’s modulus E 33 3.75 GPa
Shear modulus G 12 1.73 GPa
Shear modulus G 13, G 23 0.9 GPa
Poisson’s ratio ν 12 0.2
Poisson’s ratio ν 13, ν 23 0.17
Needled fiber region Young’s modulus E f11, E f22 3.75 GPa
Young’s modulus E f33 13.49 GPa
Shear modulus G f12 0.9 GPa
Shear modulus G f13, G f23 1.73 GPa
Poisson’s ratio ν f12 0.17
Poisson’s ratio ν f13, ν f23 0.2
Tufted fiber layer Young’s modulus e 4.9 GPa
Poisson’s ratio ν 0.21

2.2 Imposition of boundary conditions

From the theory of composite mechanics, it is clear that to calculate the stiffness properties of the RVE requires the imposition of periodic boundary conditions on it [11,12,13,14]. To simplify the computational process, the EasyPBC plug-in [15] in ABAQUS software is used in this article to impose periodic boundary conditions and thus obtain the mechanical properties of representative volume cells [8]. EasyPBC is an ABAQUS plug-in tool developed and designed by Dr. Sadik Omairey et al. [15] of Brunel Center for Composites and developed to estimate the user-created homogeneous effective elastic properties of periodically representative volumetric cells.

2.3 Calculation of the material parameters of RVE

By careful observation of the material morphology, the structure was divided into three RVEs. Also, for the statistical analysis of the observed images [16], Table 2 shows the geometric parameters of the RVE. The voxel mesh finite element models of the three RVEs were obtained by running the Python program under the ABAQUS.

Table 2

Geometric parameters of the RVE

Height H The height of plain fabric layer H 1 The height of tufted fiber layer H 2 Width W Length L The radius of needled region R n
1.2 mm 0.4 mm 0.2 mm 1.2 mm 1.2 mm 0.15 mm

We divided the entire model into 50 × 50 × 50 square voxels [17] and wrote them into a Python file, which can be run in the EasyPBC plug-in for ABAQUS to obtain the mechanical properties of the RVE.

  1. Figure 1 demonstrates that RVE-A is a single cell that has not been needled and contains two layers of woven fabric and two layers of mesh tires.

  2. RVE-B denotes the general needling region, formed by the deflection of the fibers of the woven fabrics and mesh tires along the z direction during the needling process. The geometrical path of the deflection is described by Equation (1), which can be obtained from Figure 2, where H d denotes the fiber deflection depth, H d is taken to be 0.8 mm, R n is the radius of the needle-punched area, and R e is the radius of the needle-punched fiber bundle.

    (1) z = H d sin π ( x 2 + y 2 ) − R n 2 R e

  3. RVE-C is the surface pinning region, which is located on the surface of the composite, where the fibers are pushed to the sides due to the low bonding forces on the surface woven fabric and mesh tires. Figure 3 shows some observations and literature analysis of this region [18]. Figure 4 shows the ABAQUS finite element model of RVE-C, a and b are the full cross-section and half cross-section, respectively.

Figure 1 RVE-A FE models.
Figure 1

RVE-A FE models.

Figure 2 RVE-B FE models. (a) Full section and (b) half section.
Figure 2

RVE-B FE models. (a) Full section and (b) half section.

Figure 3 Schematic representation of one-layer needled plain fabric.
Figure 3

Schematic representation of one-layer needled plain fabric.

Figure 4 RVE-C FE models. (a) Full section and (b) half section.
Figure 4

RVE-C FE models. (a) Full section and (b) half section.

The three finite element models are given the material properties in Section 2.1, and the ABAQUS plug-in EasyPBC can be used to impose periodic boundary conditions, It is possible to calculate the mechanical parameters of the three RVEs units obtained, as shown in Table 3. The stress clouds of RVE-A, RVE-B, and RVE-C can be obtained by ABAQUS software calculation, where 1/4 of the cross-section of RVE-B is taken to analyze the stress variation, as shown in Figure 5 According to Table 3, it can be seen that the elastic modulus in the x, y direction is reduced due to the deflection and migration of the fibers in part of the face to the z direction.

Table 3

Mechanical properties of RVEs

RVE-A RVE-B RVE-C
E 11, E 22 10.57 GPa 9.47 GPa 10.04 GPa
E 33 4.12 GPa 4.72 GPa 4.68 GPa
ν 12 0.21 0.20 0.20
ν 13, ν 23 0.21 0.20 0.21
G 12 2.29 GPa 1.77 GPa 1.75 GPa
G 13, G 23 2.25 GPa 1.19 GPa 1.12 GPa
Figure 5 Mises stress contours of a quarter of the RVE-B. (a) Tension in the x direction, (b) tension in the z direction, (c) shear in the xy direction, and (d) shear in the xz direction.
Figure 5

Mises stress contours of a quarter of the RVE-B. (a) Tension in the x direction, (b) tension in the z direction, (c) shear in the xy direction, and (d) shear in the xz direction.

3 Mechanical properties of periodic unit cell

The mechanical properties of the three RVEs were brought into a periodic single cell for computation. The length of the periodic cell was 10 mm, and all cells had pinholes with a pinhole diameter of 0.3 mm. The periodic cell has a 6-node triangular mesh with a total of 2,184 elements. In the finite element calculations, the different elements are defined as the mechanical properties of three representative volume cells (as shown in Figure 6).

Figure 6 Meshing of materials. (a) Unit cell and (b) needled fiber region.
Figure 6

Meshing of materials. (a) Unit cell and (b) needled fiber region.

The blue area corresponds to the mechanical properties of the superficial pinning region (RVE-C) with four mesh cells per pinning region, the remaining pinning region mesh cells are yellow areas, which correspond to the common pinning region (RVE-B), and the remaining part of the mesh cells correspond to the non-pinning region (RVE-A).

By applying periodic boundary conditions to the unit cell shown in Figure 7 with the EasyPBC plug-in in ABAQUS, four models can be obtained, representing the results subjected to x-directional tension, z-directional tension, xy-directional shear, and xz-directional shear, respectively. Figure 7 shows the stress clouds near the pinning region under the four boundary conditions. The final calculation results of the periodic single cell by EasyPBC plug-in in ABAQUS are shown in Table 4. Meanwhile, a pinning area was selected for analysis, as shown in Figure 8, the stresses in the pinning area varied significantly at both ends, and the stresses in the middle remained almost the same.

Figure 7 Stress distribution of UC in different boundary conditions. (a) Tension in the x direction, (b) tension in the z direction, (c) shear in the xy direction, and (d) shear in the xz direction.
Figure 7

Stress distribution of UC in different boundary conditions. (a) Tension in the x direction, (b) tension in the z direction, (c) shear in the xy direction, and (d) shear in the xz direction.

Table 4

Mechanical properties of UCs

E 11 E 22 E 33 ν 12 ν 13 ν 23 G 12 G 13 G 23
10.57 GPa 10.57 GPa 23.22 GPa 0.210 0.210 0.210 2.29 GPa 2.25 GPa 2.25 GPa
Figure 8 Stress distribution of needled fiber region in different boundary conditions. (a) Tension in the x direction, (b) tension in the z direction, (c) shear in the xy direction, and (d) shear in the xz direction.
Figure 8

Stress distribution of needled fiber region in different boundary conditions. (a) Tension in the x direction, (b) tension in the z direction, (c) shear in the xy direction, and (d) shear in the xz direction.

4 Factors affecting the mechanical properties of needled composites

Previous studies and analyses have found that several factors such as needling density, needling form, and needling depth widely affect the mechanical parameters of needled quartz fiber composites [19,20], so this section focuses on the effects of three factors, namely needling density, needling form, and needling depth, on the mechanical properties of needled composites.

4.1 Effect of needling density and needling distribution

The periodic single cell needling densities were 4, 9, 16, 25, and 36 needles/cm2, and the needle distribution forms were uniform and random (Figure 9). Based on the ABAQUS/Python platform, the finite element model was established and the triangular mesh was used for meshing. The mechanical properties of the needled composites can be calculated for 10 needle-punching densities using the EasyPBC plug-in of ABAQUS software.

Figure 9 Distribution of pinholes.
Figure 9

Distribution of pinholes.

From Figure 10, it can be seen that the x, y modulus of elasticity E 11 decreases gradually with increasing needling density, while the z-direction modulus of elasticity E 33 increases gradually. For shear modulus G 12 and G 13 and Poisson’s ratio ν 12 and ν 13, both decrease with increasing needling density. In the case of the needling form, as shown in Figure 10, the effect of random and uniform needling on the mechanical properties of the composite is very small, and the above conclusions can be drawn for different needling densities. Therefore, for future modeling, the random needling model can be replaced by the uniform needling model, which can simplify the modeling process.

Figure 10 Effect of needle density (a) E 11, (b) E 33, (c) ν 12, (d) ν 12, (e) G 12, and (f) G 13.
Figure 10

Effect of needle density (a) E 11, (b) E 33, (c) ν 12, (d) ν 12, (e) G 12, and (f) G 13.

4.2 Effect of needling depth

This section analyzes the effect of different needling depths on the mechanical properties of the composites. The random needling of 36 needles/cm2 in Section 4.1 was selected, and the ABAQUS/Python software platform was used to control the depth of needling by taking the needling depths of 2, 4, and 6 mm and using triangular mesh for meshing. The comparison of E 11, E 33, v 12, v 13, G 12, and G 13 was carried out for the composites with different needling depths. According to Figure 11, the tensile modulus E 11 in the x direction decreases gradually with the increase of the needling depth, while the tensile modulus E 33 in the z direction becomes larger gradually. The Poisson’s ratio ν and the shear modulus G of the composites both decrease with the increase of the needling depth.

Figure 11 Effect of needling depth. (a) E11 and E33, (b) V12 and V13, and (c) G12 and G13.
Figure 11

Effect of needling depth. (a) E11 and E33, (b) V12 and V13, and (c) G12 and G13.

5 Conclusions

Based on the fine structure of needled composites, three RVE models are proposed and computationally analyzed to obtain periodic unit cells to simulate and predict the overall mechanical properties of needled composite structures. It can be seen that the increase in the density and depth of needling significantly reduces the in-plane elastic properties of the needled composites, which in turn enhances the out-of-plane elastic properties. The effect of the form of needling on the mechanical properties of the composites is negligible and can be ignored in finite element modeling.

Acknowledgements

The authors are grateful for the reviewer’s valuable comments that improved the manuscript.

  1. Funding information: This work is supported by the Fund Program for the Scientific Activities of Selected Returned Overseas Professionals in Shanxi Province (Grant No. 20240039) and Fundamental Research Program of Shanxi Province (Grant No. 202103021224111).

  2. Author contributions: All authors have accepted responsibility for the entire content of this manuscript and consented to its submission to the journal, reviewed all the results, and approved the final version of the manuscript. Conceptualization, WN; methodology, WN and XY; software, WN and HS; investigation, ZG; formal analysis, WN and XY; writing – original draft preparation, WN; writing – review and editing, XY and ZG; visualization, HS; project administration, XY; funding acquisition, WN and ZG.

  3. Conflict of interest: Authors state no conflict of interest.

  4. Data availability statement: The data presented in this study are available on request from the corresponding author.

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Received: 2024-03-18
Revised: 2024-09-22
Accepted: 2024-10-14
Published Online: 2024-11-15

© 2024 the author(s), published by De Gruyter

This work is licensed under the Creative Commons Attribution 4.0 International License.

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https://doi.org/10.1515/secm-2024-0044
Keywords for this article
composites; mechanical properties; simulation; multi-scale; needle punched
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  28. Influence of tin additions on the corrosion passivation of TiZrTa alloy in sodium chloride solutions
  29. Microstructure and finite element analysis of Mo2C-diamond/Cu composites by spark plasma sintering
  30. Low-velocity impact response optimization of the foam-cored sandwich panels with CFRP skins for electric aircraft fuselage skin application
  31. Research on the carbonation resistance and improvement technology of fully recycled aggregate concrete
  32. Study on the basic properties of iron tailings powder-desulfurization ash mine filling cementitious material
  33. Preparation and mechanical properties of the 2.5D carbon glass hybrid woven composite materials
  34. Improvement on interfacial properties of CuW and CuCr bimetallic materials with high-entropy alloy interlayers via infiltration method
  35. Investigation properties of ultra-high performance concrete incorporating pond ash
  36. Effects of binder paste-to-aggregate ratio and polypropylene fiber content on the performance of high-flowability steel fiber-reinforced concrete for slab/deck overlays
  37. Interfacial bonding characteristics of multi-walled carbon nanotube/ultralight foamed concrete
  38. Classification of damping properties of fabric-reinforced flat beam-like specimens by a degree of ondulation implying a mesomechanic kinematic
  39. Influence of mica paper surface modification on the water resistance of mica paper/organic silicone resin composites
  40. Impact of cooling methods on the corrosion behavior of AA6063 aluminum alloy in a chloride solution
  41. Wear mechanism analysis of internal chip removal drill for CFRP drilling
  42. Investigation on acoustic properties of metal hollow sphere A356 aluminum matrix composites
  43. Uniaxial compression stress–strain relationship of fully aeolian sand concrete at low temperatures
  44. Experimental study on the influence of aggregate morphology on concrete interfacial properties
  45. Intelligent sportswear design: Innovative applications based on conjugated nanomaterials
  46. Research on the equivalent stretching mechanical properties of Nomex honeycomb core considering the effect of resin coating
  47. Numerical analysis and experimental research on the vibration performance of concrete vibration table in PC components
  48. Assessment of mechanical and biological properties of Ti–31Nb–7.7Zr alloy for spinal surgery implant
  49. Theoretical research on load distribution of composite pre-tightened teeth connections embedded with soft layers
  50. Coupling design features of material surface treatment for ceramic products based on ResNet
  51. Optimizing superelastic shape-memory alloy fibers for enhancing the pullout performance in engineered cementitious composites
  52. Multi-scale finite element simulation of needle-punched quartz fiber reinforced composites
  53. Thermo-mechanical coupling behavior of needle-punched carbon/carbon composites
  54. Influence of composite material laying parameters on the load-carrying capacity of type IV hydrogen storage vessel
  55. Review Articles
  56. Effect of carbon nanotubes on mechanical properties of aluminum matrix composites: A review
  57. On in-house developed feedstock filament of polymer and polymeric composites and their recycling process – A comprehensive review
  58. Research progress on freeze–thaw constitutive model of concrete based on damage mechanics
  59. A bibliometric and content analysis of research trends in paver blocks: Mapping the scientific landscape
  60. Bibliometric analysis of stone column research trends: A Web of Science perspective
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