B8 Composites — J.C.

Tan — HT 2023 1/10

Examples Sheet on Composites for Paper B8

TABLE OF MATERIAL PROPERTIES:

Use these data in the questions that follow

Density Tensile Poisson's Tensile Coeff. of

modulus ratio strength linear
thermal
expansion
r E n s* a
(kg/m3) (GPa) (MPa) -6 -1
(10 K )

E-glass fibre 2540 76 0.22 1800 5

Carbon fibre (high 1860 340(7) 0.35 2500 -1.2(27)
modulus)
Carbon fibre (high 1790 230(13) 0.25 3200 -1.2(27)
strength)
Kevlar fibre 1450 124(5) 0.35 2800 -2(59)
Boron fibre 2600 400 0.20 3400 5
Epoxy resin 1300 2.4 0.34 60 60
Thermoset polyester 1280 3.0 0.38 55 75

Note: Where fibres are anisotropic, values given refer to the fibre axis
direction, except values in brackets, which refer to the radial direction.
 B8 Composites — J.C. Tan — HT 2023 2/10
QUESTIONS:
1. (a) A composite consists of 65% (by mass) high strength carbon
fibres in a matrix of epoxy resin. Calculate the volume
fraction of fibres, assuming there are no voids in the
composite. If the measured density of the composite is 1550
kg/m3, calculate the void fraction.

(b) A carbon fibre/epoxy pre-preg consists of a plain weave

fabric of high modulus carbon fibre rovings, impregnated with
partially cured epoxy resin. The rovings are known to have a
linear density of 795 mg/m and their spacing is 5 mm in both
warp and weft. The total weight per unit area of the pre-preg
is 0.45 kg/m2. Treating the resulting composite material as a
[0/90] laminate, calculate the volume fraction of fibres in each
ply.

2. Rods made of unidirectional, continuous fibre composite are to be

produced as follows (percentages shown are fibre volume
fractions):

(a) 50% E-glass fibre in epoxy resin;

(b) 60% Carbon fibres (high modulus form) in epoxy resin;
(c) 60% Kevlar fibres in epoxy resin.

Predict the axial tensile modulus and specific modulus for (a) - (c),
and explain and justify any approximations you employ.
 B8 Composites — J.C. Tan — HT 2023 3/10
3. An E-glass fibre/polyester composite tube is carefully constructed
with the objective of achieving maximum axial tensile modulus.
The glass fibres are continuous and highly aligned parallel to the
tube axis. The tube contains 70% by volume glass, and has
dimensions: length 1 m, diameter 50 mm, and wall thickness 1 mm.

(a) For each loading condition below, estimate the relevant

elastic constants of the tube wall using the simple rule of
mixtures equations, and explain the approximations these
involve, concerning the distribution of stress within the
composite. Hence calculate the deformations of the tube.

(i) The changes in length and diameter when the tube

carries an axial tensile load of 10 kN;

(ii) The change in diameter when the tube is internally

pressurised (with closed ends) to a pressure of 400
kPa;

(iii) The relative rotation of the tube ends when it is

subjected to an axial torque of 30 Nm.

(b) Calculate the reduced (plane stress) stiffness matrix [Q] of

the tube wall, with respect to axes parallel and perpendicular
to its axis.
 B8 Composites — J.C. Tan — HT 2023 4/10
4. For each of the following fibre composite systems, calculate the
fibre mass fraction required to bring the axial coefficient of thermal
expansion to zero (assume fibres are aligned and continuous and
that transverse constraint between fibres and matrix can be ignored
relative to the axial constraint):

(a) Carbon fibres (high modulus form) in epoxy;

(b) Kevlar fibres in epoxy.

In each case, also find the corresponding value of transverse

coefficient of thermal expansion.

Hint: note that both fibres are anisotropic.

5. For each of the fibre composite rods described in Question 2,

predict the axial tensile strength.

6. An E-glass fibre/epoxy thin-walled tube, of length 2 m and diameter

100 mm, has a fibre volume fraction of 60%. The fibres are
continuous and parallel, and are wound spirally around the tube at
45o to the tube axis.

The tube is loaded to failure in axial tension. Predict the failure

stress and describe the mode of failure. The wall of the tube may
be taken to have a tensile strength perpendicular to the fibres and
shear strength parallel to the fibres respectively:

s2* = 40 MPa and t12* = 60 MPa.

 B8 Composites — J.C. Tan — HT 2023 5/10
7. A unidirectional fibre composite plate consists of aligned high
strength carbon fibres in a matrix of epoxy resin. Elastic constants
referred to axes 1 and 2 parallel and perpendicular to the fibres
respectively are:

E1 = 130 GPa, E2 = 7.4 GPa, n12 = 0.28, G12 = 5.58 GPa.

(a) Calculate the reduced (plane stress) stiffness matrix [Q] for
the plate.

(b) The plate is subjected, in plane stress, to in-plane strains e1 =

10-3, e2 = 5 x 10-4. Calculate the stresses s1, s2.

(c) The plate has tensile strengths parallel and perpendicular to

the fibres as follows s1T* = 1850 MPa, s2T* = 20 MPa, and
compressive strengths s1C* = 735 MPa, s2C* = 140 MPa. The
plate is subjected to pure bending deformation. In each of
the following cases, predict the bending strain at which failure
commences, and the mode of failure.

(i) Bending about axis 1.

(ii) Bending about axis 2.

Hint: In part (c), recall that in plate bending the in-plane strain is
zero in the direction parallel to the axis of bending.
 B8 Composites — J.C. Tan — HT 2023 6/10
8. A composite laminate is constructed from 4 identical unidirectional
laminae of boron fibres in epoxy resin, arranged in the following
stacking sequence: [0/90/90/0] (which can be abbreviated to
[0/90]s). The elastic constants of each lamina, referred to axes 1
and 2, parallel and perpendicular to the fibres respectively are: E1 =
207 GPa, E2 = 22.1 GPa, n12 = 0.38, G12 = 7.25 GPa. The
thickness of each lamina is 1 mm and the fibre volume fraction is
50%.

(a) Calculate the [A] stiffness matrix for the laminate, relating in-
plane loads per unit width to in-plane strains, with respect to
symmetry axes Ox, Oy.

(b) If the laminate is subject to strains in x and y directions exx =

3´10-3, eyy = 1´10-3, find the loads per unit width Nxx, Nyy.

(c) Laminae as described above are used to construct a panel of

an aircraft which will be subjected in plane stress to
simultaneous strains exx = eyy = 10-3. It is proposed to use 4n
laminae in a laminate with stacking sequence [0/90]ns. If the
design requirement is that the minimum in-plane load carried
per unit width Nxx = Nyy = 1.5 MN/m under these
circumstances, find the minimum value of n required.
Calculate the resulting mass per square metre of the panel,
and hence the percentage weight-saving when compared to
a panel made of aluminium alloy with E = 70 GPa, n = 0.33
and density r = 2800 kg/m3.
 B8 Composites — J.C. Tan — HT 2023 7/10
9. The wall of a cylindrical pressure vessel with closed ends is to be
manufactured from 10n carbon fibre/epoxy laminae, each with the
same structure and material properties as the plate described in
Question 7. The proposed stacking sequence is: [0/±45/902]ns,
where reference axes Ox, Oy are taken in the axial and hoop
directions respectively. Each lamina is of thickness 0.5 mm.

(a) For loads per unit width Nx Ny applied at the mid-plane:-

(i) explain why no axial torque is required to prevent the

cylinder twisting about its axis;

(ii) explain why no bending moments are required to

prevent the cylinder wall bending.

(b) Calculate the [A] stiffness matrix of the laminate with respect
to axes Ox, Oy, in terms of n.

(c) Calculate the ratio of in-plane strains ex/ey, when the vessel is
internally pressurised.

(d) Considering each of the laminae in turn: 0o, +45o, -45o and
90o, find the value of ey at which it will fail when the vessel is
internally pressurised, assuming other laminae do not fail
first. Use strengths given in Question 7, together with the
lamina shear strength t12* = 68 MPa.

(e) The cylindrical vessel is to form a connecting passage of an

orbiting space-station. It will be of diameter 3 m and will be
 B8 Composites — J.C. Tan — HT 2023 8/10
internally pressurised to 1 atmosphere (101.3 kPa). Find the
minimum value of n required, to ensure a factor of safety of at
least 8 against failure of any of the laminae.

Hints:
(1) Use equations for rotation of axes of [Q] given in lecture
notes.
(2) Use elements of [Q] calculated in your answer to
Question 7.
(3) Use the maximum stress failure criterion.

10. Unidirectional laminae consisting of continuous Kevlar fibres in a

matrix of epoxy resin have the following elastic constants with
respect to axes 1,2 parallel and perpendicular to the fibres:

E1 = 73 GPa , E2 = 5.0 GPa, G12 = 2.8 GPa, n12 = 0.35.

Each lamina has thickness 0.125 mm.

(a) Calculate the lamina [Q] matrix.

(b) Calculate the [A] stiffness matrix of a laminate produced from

laminae as described above, arranged in the stacking
sequence [0/±60]2s. For any laminate with this stacking
sequence, the [A] matrix is invariant under rotation of axes in
its plane. Demonstrate this with respect to the Kevlar/epoxy
laminate, by considering rotation of axes for one element of
[A], e.g. A11.
 B8 Composites — J.C. Tan — HT 2023 9/10
(c) Calculate terms D11, D22, of the [D] bending stiffness matrix of
the laminate, and hence demonstrate that bending stiffness is
not invariant under rotation of axes.

ANSWERS:

Q1. (a) 0.574, 0.0202

(b) 0.627.

Q2. 39.2, 205, 75.4 GPa; 20.4, 125, 54.2 MPa m3kg-1.

Q3. (a) (i) 1.18, -0.0158 mm;

(ii) 53 µm
(iii) 5.23o.
(b) Q11 = 54.8, Q12 = Q21 = 2.48, Q22 = 9.27, Q66 = 3.35 GPa.
Other terms = 0.

Q4. (a) 0.336; a2 = 66.4 µm/mK

(b) 0.393; a2 = 72.3 µm/mK

Q5. (a) 928,

(b) 1507,
(c) 1702 MPa.

Q6. 80 MPa, transverse tensile fracture.

Q7. (a) Q11 = 131, Q12 = Q21 = 2.08, Q22 = 7.43, Q66 = 5.58 GPa.
Other terms = 0.
(b) s1 = 132, s2 = 5.80 MPa.
 B8 Composites — J.C. Tan — HT 2023 10/10
(c) (i) 0.00269, transverse tensile fracture on convex surface.
(ii) 0.00563, axial compression failure on concave surface.

Q8. (a) A11 = 465, A12 = A21 = 34.1, A22 = 465, A66 = 29 MN/m. Other
terms = 0.
(b) Nx = 1430, Ny = 568 kN/m.
(c) n = 3, 23.2 kg/m2, 41.8% weight saving.

Q9. (b) A11 = 228n, A12 = A21 = 66.2n, A22 = 351n, A66 = 83.7 MN/m.
Other terms = 0.
(c) ex/ey = 0.562.
(d) 0o: 0.00233; ±45o: 0.00269; 90o: 0.00320
(e) n = 2.

Q10. (a) Q11 = 73.6, Q12 = Q21 = 1.77, Q22 = 5.04, Q66 = 2.8 GPa.
Other terms = 0.
(b) A11 = 47.0, A12 = A21 = 14.6, A22 = 47.0, A66 = 16.2 MN/m.
Other terms = 0.
(c) D11 = 12.0, D22 = 6.86 Nm.

Revision history:
Jan 2012 - C.P. Buckley
Nov 2013, Dec 2022 - J.C. Tan