Finite element model of fiber volume effect on the mechanical performance of additively manufactured carbon fiber reinforced plastic composites

Advancements in additively manufactured (AM) carbon-fiber-reinforced-plastic (CFRP) composites for structural applications require reliable tools to predict mechanical performance. Already, the composites are finding applications in wind turbines, Unmanned Aerial Vehicles (UAVs), space applications, etc., and are promising for more emerging needs. Fiber volume plays a huge role in influencing the mechanical performance of the composites. However, more understanding of their effects are still needed to better ascertain material performance, which can be achieved by applying simulation modeling. This study developed a micromechanical model from Python scripts for Abaqus command line within computer-aided engineering (CAE) environment to predict the
composites’ structural stability and mechanical performance. The verification of the finite element model by experimental testing showed both the simulation and experimental results to match within an acceptable range. Tensile modulus increased with fiber volume while compressive modulus shows some decreased properties with fiber addition irrespective of fiber content for up to 25% CF volume. The overall results show a possible trade-off between the tensile and compressive properties of the composite, which should be carefully considered in material design for various AM applications.