Stochastic laminate analogy for simulating the variability in modulus of discontinuous composite materials

Recent composite technology research and development efforts have focused on discontinuous carbon fiber/epoxy molding systems derived from chopped aerospace-grade unidirectional tape prepreg. Although the average elastic modulus of this material has been shown to be as high as that of the continuous tape quasi-isotropic benchmark, experimental measurement by means of strain gage or extensometer has shown variation as high as 20%. Digital Image Correlation can be used successfully to obtain a full-field strain measurement, and it shows that a highly non-uniform strain distribution exists on the surface of the specimen, with distinct peaks and valleys. This pattern of alternating regions of high and low strain gradients, and which exhibit a characteristic shape and size, can be described in terms of Random Representative Volume Element (RRVE). The RRVE proposed here exhibits random elastic properties, which are assigned based on stochastic distributions. This approach leads to the analysis method proposed here, which is designed to compensate for the fact that traditional methods cannot capture the experimentally observed variation in modulus within a specimen and among different specimens. The method utilizes a randomization process to generate statistical distributions of fractions and orientations of chips within the RRVE, and then applies Classical Laminated Plate Theory to an equivalent quasi-isotropic tape laminate to calculate its average elastic properties. Validation of this method is shown as it applies to a finite element model that discretizes the structure in multiple RRVEs, whose properties are generated independently of the neighboring ones, and then are solved simultaneously. The approach generates accurate predictions of the strain distribution on the surface of the specimen.