FUNDAMENTALS OF COMPOSITE MATERIALS VINCENT K. S. CHOO Department of Mechanical Engineering New Mexico State University New Mexico, U.S.A. KNOWEN ACADEMIC PRESS, INC., DOVER, DELAWARE, U.S.A. ‘KNOWEN}©1990 by KNOWEN ACADEMIC PRESS, INC., by KNOY All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of the publisher. Printed in the United States of America Library of Congress Cataloging in Publication Data Choo, Vincent K. S. Fundamentals of Composite Materials Includes bibliographical references and index 1, Mechanics 2. Composite Materials ISBN 0-929785-00-2In memory of Mrs. Lina Freeburg and Mrs Lin Yin ChooDe afane FIClLace Composite materials present unique challenges to the traditional roles of material acientists and engineers. A composite material can be custom tailored to have specific properties that will meet special requirements. However, a com- posite material has added dimensions of complexity with respect to engineering analyses which involve complicated mathematical models. These models may be constructed using tensor notation which lends itself well in affording a means of formulating compact mathematical models and yet contain a large amount of information. This book has been arranged consistently to present the mechanics of composite materials using Cartesian tensors as a shorthand. It introduces students to the fundamental concepts of the mechanical behavior of composite materials. In addition, it provides a solid foundation for further study and re- search. This book is based on a one-semester graduate course that I give. It is intented as a graduate level textbook. However, it may be used by students, researchers and practicing engineers for reference. ‘The first chapter provides a general introduction to composite materials. Chapter 2 discusses the second rank strain tensor. The transformation rules for a strain tensor are established clearly to show the reader how a strain tensor may be transformed from one coordinate system to the next. In chapter 3, it is shown that a stress tensor has the same transformation rules as a strain tensor. An elastic constitutive model can be used to relate the strain and the stress tensors as demonstrated in chapter 4. Fundamental to the constitutive model is the fourth rank material elastic stiffness tensor. Its transformation rules are explained. This chapter illustrates the differences among anisotropic, orthotropic and isotropic materials by examining their respective elastic material stiffness tensors. Knowledge gained from chapters 2, 3 and 4 is applied to the study of the mechanics of a lamina in chapter 5. Here, the mechanical behavior of a lamina is presented. The coupling between in-plane normal stresses and in-plane shear strain is examined. A lamina normally serves as a building block for a laminate due to limitations in engineering applications of the lamina. For the purpose of studying a laminate, the classical lamination theory is discussed in chapter 6. In general, the coupling stiffness tensors of laminated composite plates or shells are Non-zero. As a consequence, there is coupling between bending and stretching. ‘The classical lamination theory provides a means of studying the mechanicalbehavior of a laminate. Chapter 7 examines the laminated plate theory. General governing equations for bending and buckling of laminated plates are derived. A brief discussion on the thermal stresses in composites is given in chapter 8. This chapter shows that the classical lamination theory breaks down in the vicinity of a laminate edge. It is due to the edge effects which are peculiar to laminated composites. A detailed discussion on the edge effects is also included. Failure criteria of composite materials which are important in engineering design are examined in chapter 9. It has taken more than a hundred years to develop the failure criteria for isotropic materiais. Comparatively, the development of failure criteria for composite materials is still in its infancy. A basic groundwork is built from chapter 2 through chapter 9 for the study of the macromechanics of composites. In these chapters, no mention was made of the roles played by the constituent materials. Nevertheless, a knowledge on the micro-level is essential since the properties of the constituent materials clearly affect the properties of their composite materials. A brief introduction on the complicated but important topic of micromechanics is given in the final chapter. I am indebted to my wife, Charlene, and children. Without their pa- tience and support it would have been impossible for me to undertake such a project. Thanks are due to Drs. George P. Sendeckyj, Nicholas J. Pagano and James M. Whitney, of the Wright-Patterson Air Force Materials Laboratory, and Dr. Stephen W. Tsai, of Stanford University, for their generosity and kindness to review the various chapters of this book. Their highly regarded opinions have been very helpful to me in the preparation of this text. Thanks are also due to Mr. John H. Chesson, Dr Sali G. Ma, Mr. John Tipton and Mr. Toby R. Maes, of General Electric, for their interests in the composites and polymers program at New Mexico State University. I am grateful for the financial support provided by the Polymers Division of the American Chemical Society and the GE Foun- dation. I also like to thank Dr. Ron J. Pederson, who is a very kind and helpful colleague, for his assistance and advice in the preparation of this book. I am grateful for the opportunity to work with and learn from Dr Dennis D. Davis and Mr. Joe L. Creed. Thanks are due to my graduates students who have provided many valuable inputs. . Ch:CHAPTER 1 INTRODUCTION CHAPTER 2 STRAIN TENSOR 24 2.2 23 24 25 CHAPTER 3 STRESS TENSOR 3.1 3.2 3.3 CHAPTER 4 CONSTITUTIVE EQUATIONS 4. 4.2 43 44 45 INTRODUCTION INFINITESIMAL DEFORMATION STRAIN TENSOR TRANSFORMATIO! STRAIN AND DISPLACEMENT ...... THE EQUATIONS OF COMPATIBILITY EXERCISES REFERENCES INTRODUCTION STRESS TENSOR TRANSFORMATION EQUILIBRIUM EQUATIONS EXERCISES REFRRENCES INTRODUCTION wees APPLICATIONS OF THE LAWS OF THERMODYNAMICS IN MATERIAL DEFORMATIONS .. ‘TRANSFORMATION OF THE MATERIAL ELASTIC STIFFNESS TENSOR... TRANSFORMATION OF THE MATERIAL COMPLIANCE TENSOR THR CONSTITUTIVE RELATIONS 4.5.1 Monoclinic Material 4.5.2 Orthotropic Material 4.5.2 Isotropic Material EXERCISES iz Al 43 44 a7 50 53 582 contenrs REFERENCES CHAPTER 5 MECHANICS OF A LAMINA 5.1 INTRODUCTION 5.2 CONSTITUTIVE RELATIONS OF A LAMINA 5.3 TRANSFORMATION OF Qj;11 AND Sija1 FOR A LAMINA 3.4 BLASTIC BENAVIOR CF A LAMINA 5.5 DEFORMATION OF A CONSTRAINED — GENERALLY ORTHOTROPIC LAMINA EXERCISES REFERENCES . CHAPTER 6 MECHANICS OF A LAMINATE 6.1 INTRODUCTION ... 6.2 ASSUMPTIONS OF THE CLASSICAL LAMINATION THEORY 6.3 CLASSICAL LAMINATION THEORY 64 ELASTIC BEHAVIOR OF LAMINATED PLATES 6.4.1 Specially orthotropic Plates 6.4.2 Generally Orthotropic Plates 6.4.3 A Two-ply Laminated Plate 6.4.4 A Three-ply Laminated Plate 6.45 Balanced Laminates EXERCISES REFERENCES CHAPTER 7 ELASTIC LAMINATED PLATE THEORY 7.1 INTRODUCTION 7.2 EQUILIBRIUM EQUATIONS OF A LAMINATED PLATE 7.3 BENDING OF A SPECIALLY ORTHOTROPIC PLATE 4 VAKIALIONAL METHOD 7.4.1 Bending of a Specially Orthotropic Plate with Clamped Edges 7.8 GOVERNING BUCKLING EQU. 7.6 TRANSVERSE VIBRATION OF A LAMINATED PLATE REFERENCES CHAPTER 8 THERMAL AND EDGE EFFECTS 8.1 INTRODUCTION .... 8.2 THERMAL RESIDUAL STRESSES 8.2.1 Microscopic Thermal Residual Stresses 8.2.2 Macroscopic Thermal Residual Stresses in a Lamina 148 152 160 161 163 167 -168 169 169 1698.2.3 Macroscopic Thermal Residual Stresses in a Laminate 83 THERMAL GRADIENT 84 EDGEEFFECTS .... 8.4.1 Interlaminar Stresses in Angle-ply Laminates 8.4.2 Effect of Stacking Sequence on the EXERCISES REFERENCES CHAPTER 9 FAILURE CRITERIA AND ANISOTROPIC PLASTICITY 9.1 INTRODUCTION ..... 9.2 STRENGTHS OF UNIDIRECTIONAL LAMINAE 9.2.1 Uniaxial Loading 9.2.2 Biaxial Loading 9.3 FAILURE CRITERIA 9.3.1 Gol’denblat-Kopnov Strength Criterion for Brittle Anisotropic Materials 9.3.2 The Tsai-Wu Strength Tensor Polynomial Criterion 9.3.3 The Tsai-Wu Strain Tensor Polynomial Criterion 9.3.4 Maximum Stress Criterion 9.3.5 Maximum Strain Criterion 9.3.6 First Ply Failure Criterion 9.3.7 Last Ply Failure Criterion 9.3.8 Hashin Failure Criteria 9.4 ANISOTROPIC PLASTICITY 9.4.1, Elastic Constitutive Relations 9.4.2 Plasticity Theory for an Elastoplastic Isotropic Solid 9.4.3 Plasticity Theory for an Elastoplastic Composite Material EXERCISES REFERENCES CHAPTER 10 BEHAVIOR AT THE MICROLEVEL 10.1 INTRODUCTION 10.2 EXPERIMENTAL DETERMINATION OF THE EFFECTIVE ELASTIC STIFFNESS TENSOR 10.3 THEORETICAL PREDICTION OF THE EFFECTIVE ELASTIC STIFFNESS TENSOR 10.3.1. Variational Bounding Method 10.3.2 Strength of Material Approach 175 182 186 193 211 21 213 214 214 214 217 220 226 236 239 244 244 245 248 251 252 253 257 260 261 265 266 266 270 270 280