Edited by: Dr.

Ahmed Mudhafar Hashim

Senior Lecture – Department of Materials Eng. – College of Engineering – University of Qadisiyah

MECHANICS OF COMPOSTE MATERIALS – LECTURE 3

Discontinuous Fiber Reinforced Composites

Cost effective manufacturing often drives the use of discontinuous or “short”

reinforcing elements in composites. These materials differ from continuous
reinforced composites because the fibers do not extend throughout the entire
material. Therefore, load is not directly applied to each reinforcing element.
The properties of composites containing short discontinuous fibers depends on the
lengths of the fibers, their orientation and volume fraction. To consider the effects
of length we need to consider the stress transfer that takes place between the matrix
and fibers. When a load is applied to a composite it is applied to the matrix and
transferred to the fibers by some combination of shear and tensile or compressive
acting across the interface. The nature of the bond between the matrix material and
the fibers thus play a critical role in determining the properties of the composite.
For a composite under tension, we can think of a discontinuous fiber in the
matrix as being stretched as a result of interfacial shear stressed acting on the
surface of the fiber as shown in Figure 1. These shear stresses will be a maximum at
the ends of the fiber where it stretches the most and fall as we consider points on the
fiber will be nearer to the middle. The tensile stress in the fiber will be zero at the
ends and build up as the shear stress decreases.
Provide the fiber is long enough we can consider the shear stresses decreasing to
zero and the tensile stress rising to a maximum value in the central region of the
fiber. If the fiber in not long enough, the shear stress will not fall to zero and the
tensile stress will not reach the maximum possible value. In order to achieve this
maximum level of tensile stress, the fiber length must be at least equal to "a critical

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length ‫الطول الحرج لليف‬, lc". Figure 2 shows the tensile stress patterns we might
expect for different fiber lengths.

Figure 1. Single fiber in a matrix material.

Consider the interfacial shear stress acting on single a fiber in matrix. If τ is the
average interfacial shear stress then the shear force acting on a section of the fiber,
length x and of uniform cross – sectional diameter D as shown in Figure 3, is the:
𝑺𝒉𝒆𝒂𝒓 𝒇𝒐𝒓𝒄𝒆 = 𝑺𝒉𝒆𝒂𝒓 𝒔𝒕𝒓𝒆𝒔𝒔 × 𝒂𝒓𝒆𝒂 = 𝝉𝝅𝒅𝒙
This shear force results in the longitudinal stress in the fiber of σf. Thus:
1
𝜎𝑓 ( 𝜋𝑑 2) = 𝜏𝜋𝑑𝑥
4
and so
4𝑐𝑥
𝜎𝑓 =
𝑑

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Senior Lecture – Department of Materials Eng. – College of Engineering – University of Qadisiyah

The stress increases from zero at the end of a fiber when x = 0, to its maximum
possible value when x = (1/2)lc. Hence, the maximum value of the tensile stress is
given by:
𝟐𝝉𝒍𝒄
𝒎𝒂𝒙𝒊𝒎𝒖𝒎 𝝈𝒇 = … (𝟏)
𝒅

The critical length to diameter (lc/d) must not be less than (σf/2τ) if the composite
is to realize the potential of the fiber. For a glass fiber – polyester composite the
maximum value of stress the fibers can withstand is 1500 MPa and the shear stress
is 25 MPa, the (lc/d) is 30. For fibers of diameter 5 µm then Lc is 0.15 mm. If the
fibers used are of greater diameter then the critical length is increased. Table 1
shows some typical values of the (lc/d) ratio.

Table 1. Typical values of (lc/d) ratio.

Fiber Matrix (lc/d) ratio

Glass Polyester 30
Glass Polypropylene, PP 140

Carbon Epoxy 35
Boron Epoxy 35
SiC Aluminum 10
Al2O3 Aluminum 20

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Senior Lecture – Department of Materials Eng. – College of Engineering – University of Qadisiyah

If the fiber length l is longer than the critical length and we assume a linear
variation of stress with distance, as shown in Figure 2b, the average tensile stress in
the fiber is given by taking the area under the stress – fiber graph and dividing by
the fiber length:

 1  max . f
Average stress  L - L c    …(2)
 2 L
 L 
 1 - c  max . f
 2L 
…(3)
 L  2L
 1 - c  c
 2L  d

When the fiber length is equal to the critical length, as shown in Figure 2a, then
the average tensile stress in the fiber:
𝝉𝒍𝒄
𝑨𝒗𝒆𝒓𝒂𝒈𝒆 𝒔𝒕𝒓𝒆𝒔𝒔 = … (𝟒)
𝒅
When the fiber length is less than the critical length, as shown in Figure 2c) the
tensile stress in the fiber will never reach the maximum value. The area under the
tensile – fiber graph is half the maximum stress value attained, this being (2τl/D):
𝝉𝒍
𝑨𝒗𝒆𝒓𝒂𝒈𝒆 𝒔𝒕𝒓𝒆𝒔𝒔 = … (𝟓)
𝒅
As the above equations indicate, the average stress in a short fiber will be less than
the maximum stress the fiber can withstand.

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Figure 2. Stress–position profiles when fiber length l (a) is equal to the critical
length lc (b) is greater than the critical length, and (c) is less than the critical length
for a fiber-reinforced composite that is subjected to a tensile stress equal to the
fiber tensile strength σf.

Figure 3. Shear force at fiber – matrix interface.

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Senior Lecture – Department of Materials Eng. – College of Engineering – University of Qadisiyah

Now consider the following three cases:

For l ˃ lc, the governing equation is:
𝒍𝒄
𝝈𝒄 = 𝝈𝒎 𝑽𝒎 + [(𝟏 − )𝒎𝒂𝒙𝝈𝒇 ] 𝑽𝒇 … (𝟔)
𝟐𝒍
For l = lc, the governing equation is:
𝝉𝒍𝒄
𝝈 𝒄 = 𝝈𝒎 𝑽𝒎 + [ ] 𝑽𝒇 … (𝟕)
𝒅
For l ˂ lc, the governing equation is:
𝝉𝒍
𝝈𝒄 = 𝝈𝒎 𝑽𝒎 + [ ] 𝑽𝒇 … (𝟖)
𝒅

Example No. 1: A glass fiber – polyester composite contains 60% by volume of

fibers, the fibers being of length 3 mm. If the failure stress for the fibers is 1500
MPa, the shear strength 25 MPa, and the matrix has a tensile strength of 50 MPa,
determine the strength of the composite. The diameter of the fiber is 5 µm.
Solution:
Short glass fiber/polyester composite
Vf = 60%
L = 3 mm
Maximum stress of glass fiber 1500 MPa
Bond strength 25 MPa
Strength of matrix 50 MPa
Diameter of glass fiber 5 x 10-6 mm
Maximum σf = 2τ lc/D
𝟐𝝉𝒍𝒄
𝝈𝒎𝒂𝒙 =
𝑫

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𝟐(𝟐𝟓𝑴𝑷𝒂)𝒍𝒄
𝟏𝟓𝟎𝟎 𝑴𝑷𝒂 =
5 x 10−6 mm
𝒍𝒄 = 𝟎. 𝟏𝟓 𝒎𝒎
𝒍 = 𝟑𝒎𝒎 > 𝒍𝒄 = 𝟎. 𝟏𝟓𝒎𝒎

𝒍𝒄
𝝈𝒄 = 𝝈𝒎 𝑽𝒎 + [(𝟏 − )𝒎𝒂𝒙𝝈𝒇 ] 𝑽𝒇 … (𝟔)
𝟐𝒍

𝟎. 𝟏𝟓 𝒎𝒎
𝝈𝒄 = (𝟓𝟎𝑷𝑴𝑷𝒂)(𝟎. 𝟒) + [𝟏 − )𝟏𝟓𝟎𝟎𝑴𝑷𝒂] (𝟎. 𝟔) … (𝟔)
𝟐(𝟑𝒎𝒎)
𝝈𝒄 = (𝟓𝟎𝑷𝑴𝑷𝒂)(𝟎. 𝟒) + [𝟏𝟒𝟔𝟐. 𝟓 𝑴𝑷𝒂](𝟎. 𝟔) … (𝟔)

𝝈𝒄 = 𝟖𝟗𝟕. 𝟓 𝑴𝑷𝒂

Halpin-Tsai Equations for Prediction of Moduli of Discontinued

Fiber Reinforced Composites
The tensile modulus of composites with short length fibers with the fibers all
aligned in a direction parallel to the fibers as shown in Figure 4b less than that of
the comparable aligned continuous fiber composite. A modified rule of mixture
improved by Halpin and Tsai can be used, incorporating "a length efficiency
parameter, η" to take account of the fibers not being continuous. Thus equation
(23) - Lecture No. (2) becomes:
Ec = Em Vm + η Ef Vf …(9)
where
𝑬𝒇
−𝟏
𝑬𝒎
𝜼= 𝑬𝒇 … (𝟏𝟎)
+ 𝝃𝒊
𝑬𝒎

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i indicates the two principal material directions; longitudinal (L) or transverse (T) to
the fiber direction.
The reinforcement shape parameter, ξi depends on the direction of loading and
the filler shape:
𝒍𝒇
𝝃𝑳 = 𝟐 , 𝝃𝑻 = 𝟐 …(11)
𝒙

where: x equals the fiber diameter or platelet thickness.

Sub. equations 10 and 11 in equation 9:
𝒍𝒇
𝟏 + 𝟐 ( ) 𝜼𝑳 𝑽 𝒇
𝒅𝒇
𝑬𝑳𝒄 = 𝑬𝒎 … (𝟏𝟐)
𝟏 − 𝜼𝑳 𝑽 𝒇

𝟏 + 𝟐𝜼𝑳 𝑽𝒇
𝑬𝑻𝒄 = 𝑬 … (𝟏𝟑)
𝟏 − 𝜼𝑳 𝑽 𝒇 𝒎

𝟏 + 𝜼𝑮 𝑽 𝒇
𝑮𝑳𝑻
𝒄 = 𝑬 … (𝟏𝟒)
𝟏 − 𝜼𝑮 𝑽 𝒇 𝒎
and
𝑳
𝒗𝑳𝑻 𝑳
𝒄 = 𝒗𝒎 𝑽𝒎 + 𝒗𝒇 𝑽𝒇 … (𝟏𝟓)

Where

𝑮𝒇
−𝟏
𝑮𝒎
𝜼𝑮 = 𝑮𝒇 … (𝟏𝟔)
+𝟏
𝑮𝒎

For carbon fibers of length 0.1 mm and diameter 8 µm in epoxy matrix, the
efficiency parameter, η, is 0.2. With these fibers of length 1 mm, the efficiency
parameter, η, is 0.89 and as the length increases so the parameter efficiency, η,
approaches to 1.

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The tensile modulus of composites with non – aligned (randomly) short length
fibers Figure 4c less than that giving on the alignment direction for the same short
length fibers when aligned. "An orientation efficiency parameter, η°," can used to
take account of this, equation (9) then becoming:
Ec = Em Vm + η° η Ef Vf …(17)

For completely three dimensionally random fibers, the orientation efficiency

parameter, η°, has the value of 0.2.

Figure 4. Schematic representations of (a) continuous and aligned,

(b) discontinuous and aligned, and (c) discontinuous and randomly oriented fiber
reinforced composites.

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Senior Lecture – Department of Materials Eng. – College of Engineering – University of Qadisiyah

The short fiber composite with random orientation produces the composite with
isotropic behaviour in a plane. To predict the elastic moduli of such randomly
oriented composites, the empirical formulae given below are used:
𝟑 𝟓
𝑬𝒓𝒂𝒏𝒅𝒐𝒎
𝒄 = 𝑬𝑳 + 𝑬𝑻 … (𝟏𝟖)
𝟖 𝟖

𝟏 𝟏
𝑮𝒓𝒂𝒏𝒅𝒐𝒎
𝒄 = 𝑬𝑳 + 𝑬𝑻 … (𝟏𝟗)
𝟖 𝟒
and

𝑬𝒓𝒂𝒏𝒅𝒐𝒎
𝒄
𝒗𝒓𝒂𝒏𝒅𝒐𝒎
𝒄 = − 𝟏 … (𝟐𝟎)
𝟐𝑮𝒓𝒂𝒏𝒅𝒐𝒎
𝒄

Example No. 2: Estimate the longitudinal modulus of elasticity for an aligned

discontinuous fiber composite, if the fibers constitute 40% of the volume, the fibers
have a modulus of elasticity of 400 GPa and the matrix a modulus of 5 GPa and the
length efficiency parameter is 0.8.
Solution:
Ec = Em Vm + η Ef Vf
Ec = 0.6 × 5 × 109 + 0.8 × 0.4 × 400 × 109
Ec = 131 GPa Ans.

Example No. 3: Calculate the elastic constants for the composite that consists of
randomly distributed short glass fibers 42% by volume. The diameter and the
length of the fiber used are 2.5 mm and 25 mm respectively. The Epoxy resin is
used as matrix.

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Data given
Ef = 70 GPa (assumed)
Em = 3.5 GPa (assumed)
ρ f = 2.5 g/cm3 (assumed)
ρm = 1.2 g/cm3 (assumed)
lf = 25 mm (given)
df = 2.5 mm (given)
Solution:

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Design of Polymer Matrix Composites

Example 4: Design a unidirectional fiber-reinforced epoxy-matrix strut having a
round cross section. The strut is 3 m long and, when a force of 2224 N is applied, it
should stretch no more than 0.25 cm. We want to assure that the stress acting on
the strut is less than the yield strength of the epoxy matrix, 83 MPa. If the fibers
should happen to break, the strut will stretch an extra amount but may not
catastrophically fracture. Epoxy costs about $1.8/kg and has a modulus of elasticity
of 3450 MPa.

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Homework of Lecture #3

1- Compute the longitudinal tensile strength of an aligned glass fiber–epoxy

matrix composite in which the average fiber diameter and length are 0.015
mm and 2.0 mm, respectively, and the volume fraction of fibers is 0.25.
Assume that (1) the fiber–matrix bond strength is 100 MPa, (2) the fracture
strength of the fibers is 3500 MPa psi), and (3) the matrix stress at composite
failure is 5.5 MPa.
2- Repeat these calculations in example 3 using KevlarTM fibers, with a
modulus of 124 x 103 MPa, a density of 1.44 g/cm3, and a cost of about
$44/kg.

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