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Principal strain induced fiber orientation evolution in the Csf/Mg composites with a large deformation
Journal: Journal of Composite Materials
Manuscript ID: JCM-14-0472.R2
Manuscript Type: Original Manuscript
Date Submitted by the Author: 27-Oct-2014
Complete List of Authors: Tian, Wenlong; Northwestern Polytechnical University, School of Mechanical Engineering Qi, Lehua; Northwestern Polytechnical University, School of Mechanical Engineering zhou, Jiming; Northwestern Polytechnical University, School of Mechanical Engineering Xu, Yiren
Keywords: Csf/Mg composites, Finite element analysis, Fiber orientation evolution,
Extrusion, Principal strains
Abstract:
In this article, the fiber orientation evolution in the Csf/Mg composites with a large deformation is investigated. The principal strain driveninduced fiber orientation evolution mechanism, which states that the fiber orientation evolution in the extruded Csf/Mg composites with a large deformation is determined by the principal strains, is proposed. The fiber orientation distribution factor , which is a functiontaking the form of the principal strains is proposed to quantitatively characterize the fiber orientation distribution in the extruded Csf/Mg composites. The fiber orientation factors predicted by the FE simulations based on the principal strain driveninduced fiber orientation evolution mechanism are compared against
those measured from the micrographs of the extrusion experiments of Csf/Mg composites. The results show demonstrate that the principal strain driveninduced fiber orientation evolution mechanism is valid and convenient to predict the fiber orientation evolution in the Csf/Mg composites with a large deformation. And t In the extruded Csf/Mg composites, the fibers are reoriented towards the direction of the maximum principal strain and deviated from the direction of the minimum principal strain in the extruded Csf/Mg composites with a large deformation.
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Principal strain driveninduced fiber orientation evolution in the extruded
Csf/Mg composites with a large deformation
Wenlong Tian, Lehua Qi*, Jiming Zhou, Yiren Xu
School of Mechanical Engineering, Northwestern Polytechnical University, 127
Youyi West Road, Xi’an 710072, P. R. China
*Corresponding author. Tel.: +86-29-88460447, Fax: +86-29-88491982, E-mail:
Abstract
In this article, the fiber orientation evolution in the Csf/Mg composites with a large
deformation is investigated. The principal strain driveninduced fiber orientation
evolution mechanism, which states that the fiber orientation evolution in the
extruded Csf/Mg composites with a large deformation is determined by the principal
strains, is proposed. The fiber orientation distribution factors ( 1,2 3)iF i and= F ,
which is a functiontaking the form of the principal strains is proposed to
quantitatively characterize the fiber orientation distribution in the extruded Csf/Mg
composites. The fiber orientation factors s
iF predicted by the FE simulations based
on the principal strain driveninduced fiber orientation evolution mechanism are
compared against those m
iF measured from the micrographs of the extrusion
experiments of Csf/Mg composites. The results show demonstrate that the principal
strain driveninduced fiber orientation evolution mechanism is valid and convenient
to predict the fiber orientation evolution in the Csf/Mg composites with a large
deformation. And t In the extruded Csf/Mg composites, the fibers are reoriented
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towards the direction of the maximum principal strain and deviated from the
direction of the minimum principal strain in the extruded Csf/Mg composites with a
large deformation.
Keywords: Csf/Mg composites; Extrusion; Finite element analysis; Fiber orientation
evolution; Principal strains
1. Introduction
The increasing applications of short-fiber-reinforced composites have sustained a
vigorous scientific and engineering interest in the area of the prediction of their
effective mechanical and thermal properties [1-4]. Short-carbon-fiber reinforced
magnesium alloy matrix (Csf/Mg) composites is One one typical representative of
these short-fiber-reinforced composites, which have important potentials in many
cutting-edge industries including automotive, aviation, aerospace and national
defense industries, etc., due to their lightweight, excellent mechanical properties,
low thermal expansion coefficient, and high damping capacities [51-73]. The
increasing applications of these advanced composites have sustained a vigorous
scientific and engineering interest in the area of the prediction of their effective
mechanical and physical properties [4-7]. It has been pointed out that the fiber
orientation distribution in the composites strongly influences affects the mechanical
responses of composites [8-10] on one hand. FurthermoreOn the other hand, the
processing route has a significant influence on the fiber orientation distribution in
the composites [11, 12]. Given that the effect of the processing route on the fiber
orientation evolution in the forming process of composites was understood clearly,
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the fibers might be reoriented to turn towards the predetermined directions, which
would be a great advantage for the applications of composites [13-15]. Therefore, it
is important to investigate the fiber orientation evolution in the forming process of
composites.
The motivation for the present article is the fiber orientation evolution of Csf/Mg
composites in the extrusion forming process. Until now, many attemptsresearch on
the fiber orientation of composites mainly focused on the effect of fiber orientation
on the mechanical properties of composites and the fiber orientation evolution in
the forming process of composites.
The fiber orientation evolution in the short-fiber-reinforced composites, has
received the considerable attention in the literatures. Attention The study was
initially focused on the fiber suspensions systems and the injection molding process
of composites owing to the pioneering research work of Jeffery [16], which had
become the groundwork for the later fiber suspensions flow studying. And lLots of
research works [17-20] about relating to the fiber suspensions system have has
been carried on. Regarding the fiber orientation evolution of composites in the
injection molding process of composites, many theoreticaltheory models have been
established, such as the scheme developed by Advani and Tucker [21] and Bay and
Tucker [22], the FT model [23] and two modified FT model [24-25].
Comparatively, the work towards However, less attention has been directed towards
the fiber orientation evolution in the solid forming process of composites is seldom
reported. Li [26] investigated the effect of the extrusion ratios on the rotation of the
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whiskers by using the transformation of the streamline grids to represent the flow
of the whiskers in the SiCw/6061 composites, and learned . The results showed that
the degree of the whiskers reorientation were was reoriented more intensively with
the increasing of the extrusion ratio. Su [27] studied the fiber orientation evolution
in the different axial regions of Csf/Mg composites during the extrusion forming
process, and obtained the conclusionshared the idea that with the strain increasing,
the fibers in the Csf/Mg composites were reoriented along the extrusion direction
more obviously with increasing strain.
In this article, the fiber orientation evolution of in the Csf/Mg composites in the
extrusion forming processwith a large deformation is investigated. The principal
strain driveninduced fiber orientation evolution mechanism that the fiber
orientation evolution of fibers in the Csf/Mg composites is determined by the
principal strains, is proposed. The fiber orientation distribution factors F iF areis
proposed defined to characterize the fiber orientation distribution in the Csf/Mg
composites. The fiber orientation distribution factors s
iF predicted by the FE
simulations are compared against those m
iF measured from the micrographs to
verify the validity of the principal strain driveninduced fiber orientation evolution
mechanism. Finally, the fiber orientation distribution in the extruded Csf/Mg
composites is analyzed.
2. The principal strain driveninduced fiber orientation evolution mechanism
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During the extrusion forming process of Csf/Mg composites, some hypotheses are
made in connection withregarding to the translation and rotation of short carbon
fibers:
(1) Perfect interface bonding between the fibers and matrix of Csf/Mg composites;
(2) No bending deformation of fibers;
(3) No translation and rotation interference between fibers;
(4) No fiber damage and fracture;
(5) The absolutely rRandom initial fiber orientation distribution in the Csf/Mg
composites.
Figure 1 illustrates the diagrammatic sketch of the fiber orientation evolution in the
Csf/Mg composites deforming under the transverse tensile and longitudinal
compression loads. Before Csf/Mg composites deform, the fiber orientation
distribution is absolutely random (Figure 1(a)). However, the fiber orientation
distribution changes when Csf/Mg composites deform under the applied loads.
According to the aforementioned hypotheses, the fibers will be translated and
rotated along towards the direction of the matrix deformation (Figure 1(c)).
Therefore, the final fiber orientation distribution mainly depends on the
deformation of Csf/Mg composites.
Fig.1 Diagrammatic sketch of the fiber orientation evolution in the Csf/Mg composites
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The size of short carbon fiber is far smaller than that of Csf/Mg composites,
resulting that the deformation of Csf/Mg composites, at the scale of fiber, can be
simplified to be homogeneous. Therefore, the principal strain driveninduced fiber
orientation evolution mechanism states that the final fiber orientation distribution
of the extruded Csf/Mg composites with a large deformation depends on the
principal strains of Csf/Mg composites.
In the two-dimensional space, point o is a random point in the inside of Csf/Mg
composites, and a local plane Cartesian coordinate system oxy is established. The
deformation of Csf/Mg composites is constrained in the planeoxy . The fiber length
has no effect on the fiber orientation evolution of fibers such that all the fiber length
is set to 1 length unit in the Csf/Mg composites without deformation. We can
translate all fibers in the vicinity of point o to make one end points of these fibers
coincide with point o and the other end points be located on the circle with the a
radius of 1 length unit, which is named the orientation circle and shown in Figure 2
(a). When Csf/Mg composites deform, the shape of the orientation circle becomes to
an ellipse, which accordingly is named the orientation ellipse, as shown in Figure 2
(b).
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Fig.2 The orientation circle with a radius of 1 length unit and orientation ellipse
Figure 2 illustrates that short carbon fibers are translated and rotated to the
direction of the major axis and deviated from the direction of the minor axis of the
orientation ellipse as the Csf/Mg composites deform. Note that the directions of the
maximum and minimum principal strains are consistent with the directions of the
major and minor axis axes of the orientation ellipse, respectively. Therefore, the
fibers are reoriented to the direction of the maximum principal strain and deviated
from the direction of the minimum principal strain when Csf/Mg composites have a
large deformation in the two dimensional space. FurthermoreAnalogically, the same
conclusion can be drawn when Csf/Mg composites deform in the three-dimensional
space.
3. Governing equations of the fiber orientation factor
The fiber orientation distribution probability function [22] and the fiber orientation
tensor [21] are the most used parameters to express the fiber orientation
distribution in the composites. However, in this article the fiber orientation
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distribution factors iF is are proposed to characterize the fiber orientation
distribution based on the principal strain driveninduced fiber orientation evolution
mechanism. The fiber orientation distribution factors iF arefactor F is defined for
the first time as follows: Point A represents an arbitrary point within the Csf/Mg
composites. And the vVector n is the unit direction vector of the principal strain of
the point A. Then the factors ( 1,2 3)iQ i and= is are defined to represent the
average angle between all fibers in the vicinity of the point A and its the unit
direction vectornof its principal strain. The fiber orientation distribution factors
distribution iF F is are given as,
1 sini iF Q= − ⑴
Therefore, iF F can express the orientation distribution degree of fibers fiber
orientation distribution and ranges from 0 to 1. The factor iF of 0 and 1 represents
that the fibers are perpendicular and parallel to the given directions, respectively.
Fig.3 The fiber orientation sphere and orientation ellipsoid
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In the three-dimensional space, the orientation sphere referring to the fiber
orientation becomes the orientation ellipsoid when Csf/Mg composites have a
deformation, whose major axis and two minor axes are set to be parallel to the
directions of the z , y and x axis axes of the Cartesian coordinate systemoxyz , as
shown in Figure 3. The segments OP and 'OP represent an arbitrary fiber in the
composites without and with a deformation, respectively. Here donate by 1e , 2e and
3e the maximum, mediumintermediate and minimum principal strains, respectively.
Note that the strain here refers to the engineering strain instead of the logarithmic
strain. The intercepts a , b and c of the orientation ellipsoid on the x , y and z axis
axes taking the form of 1e ,
2e and 3e can be written as
3 2 11 , 1 , 1a e b e c e= + = + = + ⑵
When Before Csf/Mg composites have no deformation, the coordinates of the point
P are given as
sin cos , sin sin , cosx y zϕ θ ϕ θ ϕ= = = ⑶
And wWhen Csf/Mg composites have a large deformation, the coordinates of the
point 'P are given as
sin cos , sin sin , cosx a y b z cϕ θ ϕ θ ϕ′ ′ ′= = = ⑷
The tangent of the angle between the segment 'OP and the z axis is given as
2 22 2
3 2
1 1
1 1tan ( , ) tan cos sin
1 1
x y e e
z e eϕ ϕ θ ϕ θ θ
′ ′ + + +′ = = + ′ + +
⑸
Letting S indicate the surface area of the fiber orientation sphere, we can get
that 4S π= . When Csf/Mg composites have a deformation, the factor 1Q is given as
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1
( , )dQ S
S
ϕ ϕ θ′= ∫∫ ⑹
where dS can be written as
d sin d dS ϕ ϕ θ= ⑺
According to the symmetry of the fiber orientation sphere and ellipsoid, the first
quadrants of the orientation sphere and ellipsoid are selected to for calculate
calculating the factor 1Q ,
/2 /2
1
0 0
( , )sin d d
/ 8Q
S
π π ϕ ϕ θϕ ϕ θ
′= ∫ ∫ ⑻
Substituting Eq. (5), the equation Eq. (8) can be rewritten
2 2
3 22 21
0 01 1
1 12sin arctan tan cos sin d d
1 1
e eQ
e e
π π
ϕ ϕ θ θ ϕ θπ
+ + = + + + ∫ ∫ ⑼
Therefore, the fiber orientation factors 1F , 2F and 3F take the form of the principal
strains and are given as
2 2
3 22 21
0 01 1
1 121 sin sin arctan tan cos sin d d
1 1
e eF
e e
π π
ϕ ϕ θ θ ϕ θπ
+ + = − + + + ∫ ∫
⑽-a
2 2
312 22
0 02 2
1121 sin sin arctan tan cos sin d d
1 1
eeF
e e
π π
ϕ ϕ θ θ ϕ θπ
++ = − + + + ∫ ∫
⑽-b
and
2 2
2 12 23
0 03 3
1 121 sin sin arctan tan cos sin d d
1 1
e eF
e e
π π
ϕ ϕ θ θ ϕ θπ
+ + = − + + + ∫ ∫
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⑽-c
4. Results and discussions
4.1 Finite element model
In this section, an FE model is simulated to acquire the principleprincipal strain field
of the extruded Csf/Mg composites. The reinforcement and matrix of Csf/Mg
composites are T300 short carbon fibers and AZ91D magnesium alloy, respectively.
The fiber volume fraction in the extruded Csf/Mg composites is about10% , and the
average fiber length and average fiber diameter are 105 mµ and7 mµ , respectively.
The extrusion forming process of Csf/Mg composites is shown in Figure 4. The
diameter of the extrusion forming mold is 45mm and the extrusion aspect ratio and
mold angle are 5 and 55o , respectively.
Fig.4 Diagrammatic sketch of the extrusion forming process of Csf/Mg composites
The axisymmetric FE model is created as shown in Figure 5. Compared with Csf/Mg
composites, the extrusion forming mold has a much larger stiffness so that the
analytical rigid body is used to represent the extrusion forming mold in the FE
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model. Because of symmetry, the displacement xu in the x-direction on the left
boundary of the FE model is constrained. On the right boundary of the FE model, the
surface-surface contact constraint is set, in which the maximum friction condition is
adopted. The extrusion velocity on the top boundary of the FE model is 1 /mm s .
Plastic strain 0 0.01 0.02 0.03 0.04
True stress/MPa 18.86 53.64 71.15 76.96 77.16
Table 1 Plastic strain-stress data of Csf/Mg composites
The extrusion process of Csf/Mg composites is instantaneous with little temperature
variation so that the effect of the temperature variation on the strain field is
ignoredneglected. Csf/Mg composites are homogenized as the effective elasto-plastic
material, at the macro level, in the extrusion forming process and the homogenized
mechanical properties of the Csf/Mg composites come from the tensile experiments.
The Elastic modulus and Poisson ratio of Csf/Mg composites are 5.3GPa and0.33 ,
respectively. The von Mises yield criterion and the isotropic hardening model are
introduced to simulate the plasticity flow of Csf/Mg composites and the plastic
properties are listed in Table 1.
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Fig.5 The FE model and its boundary conditions
The CAX4R element (A 4-node bilinear axisymmetric quadrilateral, reduced
integration, hourglass control element) is used to mesh the FE model, in which there
are 2050 elements with 2167 nodes. To solve the mesh distortion in the case of a
large deformation, the arbitrary Lagrangian-Eulerian adaptive meshing technology is
adopted [27]. Meanwhile, the mass scaling [28] method is used to improve the
calculation speed of the explicit finite element analysis.
4.2 The fiber orientation distribution factor
To verify the validity of the principal strain driveninduced fiber orientation
evolution mechanism, the fiber orientation distribution factors s
iF acquired
predicted from the FE simulations and those m
iF from the extrusion experiments
are compared. 8 sample points in the Csf/Mg composites extrusion product are
selected, which are shown in Figure 56. Note that at each sample point, five
micrographs are selected and analyzed to obtain the average fiber orientation
distribution factors. One group of the micrographs at the selected sample points is
given in Figure 56 and the sizes of these micrographs are about575 450m mµ µ× .
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Fig. 6 The positions of the selected sample points and their microstructures
The directions and magnitudes of the principal strains at the sample points,
predicted by the FE simulation (shown in Figure 8 7 and Figure 98), are given in
Table 2. Note that n is the unit direction vector of the principal strains strain, and 1e ,
2e and 3e are the magnitudes of the maximum, mediumintermediate and minimum
principal strains, respectively. Having used these magnitudes of the principal
strains,Therefore, the fiber orientation distribution factors s
iF are calculated and
listed in Table 3, in which the fiber orientation distribution factors m
iF measured
and averaged from the micrographs of the extrusion experiments of Csf/Mg
composites with an image recognition technique [30, 31] is are included. Here, the
image recognition procedures of the micrographs of are given as follows,
(1) Binarization of the images;
(2) Reconstruction of the fiber crossing sections (which are simplified to be ellipses
and Seeshown in Figure 9);
(3) Feature extraction of the elliptical crossing sections (such as the length of the
major and minor axes and the orientation of the major axis);
(4) Calculation of the unit direction vector ( , , )i i i il m n=νννν of the i th− fiber;
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(5) Calculation of the angles between the x, y and z axes and the fibers, and the
average angles, then and the fiber orientation distribution factor.
Point 1n 2n 3n 1e 2e 3e
a -0.993 0.000 -0.116 0.390 -0.167 -0.169
b -0.997 0.000 -0.072 3.235 -0.517 -0.520
c -1.000 0.000 -0.007 3.881 -0.546 -0.547
d -1.000 -0.003 0.000 2.890 -0.491 -0.496
e -0.691 0.000 -0.722 1.048 -0.047 -0.513
f -0.635 0.000 -0.772 8.186 -0.296 -0.826
g -1.000 0.000 -0.024 17.078 -0.452 -0.846
h -0.999 0.000 -0.037 3.432 -0.506 -0.546
Table 2 The directions and magnitudes of the principal strains at the sample points
Fig. 7 The magnitudes of the principal strains in the extruded Csf/Mg composites
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The fiber orientation distribution factors s
iF predicted by the FE simulations are
compared against those m
iF measured and averaged from the micrographs are
compared in Figure 10, which illustrates that the fiber orientation distribution
factors s
iF predicted by the FE simulations coincide well with those m
iF measured
and averaged from the micrographs. It This proves that the principal strain
driveninduced fiber orientation evolution mechanism is valid and the fiber
orientation distribution factors iF F is are effective and convenient to characterize
the fiber orientation distribution in the Csf/Mg composites with a large deformation.
Sample Point 1
sF 1
mF 2
sF 2
mF 3
sF 3
mF
a 0.2263 0.1369 0.1284 0.1908 0.1277 0.2006
b 0.618 0.6035 0.0279 0.0584 0.0276 0.0345
c 0.6917 0.5924 0.0185 0.026 0.018 0.0255
d 0.6145 0.5138 0.027 0.026 0.0281 0.0343
e 0.3514 0.3011 0.1288 0.151 0.0479 0.0549
f 0.7524 0.6896 0.0256 0.0531 0.0023 0.0146
g 0.9179 0.9211 0.0041 0.0114 5E-4 0.0073
h 0.6806 0.6281 0.0208 0.0335 0.0183 0.0345
Table 3 The predicted and measured fiber orientation distribution factors
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Fig. 8 The directions of the principal strains in the extruded Csf/Mg composites
Fig.9 The reconstruction of the fiber crossing sections
The fiber orientation factors s
iF predicted by the FE simulations show that the
fibers are reoriented towards the direction of the maximum principal strain and
deviated from the direction of the minimum principal strain, while the fiber
orientation degree of fibers along the direction of the mediumintermediate
principal strain ranges between that those along the directions of the maximum and
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minimum principal strain. The same results can be found from the fiber orientation
distribution factors m
iF measured from the micrographs of the extrusion
experiments of Csf/Mg composites.
Fig. 10 The fiber orientation factors iF F1, F2 and F3 predicted by the FE simulations and
measured from the micrographs
4.3 Fiber orientation distribution
The fiber orientation distribution and plastic strain field in the extruded Csf/Mg
composites are given in Figure 11 and Figure 12. According to the plastic strain field
in the extruded Csf/Mg composites, the deformation within the Csf/Mg composites
can be divided into three regions: the non-plastic deformation zone (Region 1), the
severe plastic deformation zone (Region 2) and the steady plastic deformation zone
(Region 3), as shown in Figure 13. Moreover, the Region 1 can be further divided
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into two parts: the general elastic deformation zone (Part 1, marked B and C in
Figure 13) and the dead deformation zone (Part 2, marked A in Figure 13).
Fig. 11 The fiber orientation distribution in the extruded Csf/Mg composites
Fig.12 The plastic strain field in the extruded Csf/Mg composites product
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From the fiber orientation distribution contours, it can be found that in the general
elastic deformation zone the fiber orientation maintains the approximately random
distribution, and the fibers closing to the extrusion mold are slightly reoriented
along the direction of the maximum principal strain. However, in the severe plastic
deformation zone, the fiber orientation has the following characteristics: the fibers
in the composites near the extrusion mold are approximately reoriented along the
tapered surface generatrix of the extrusion mold. And tThe fiber orientation of
fibers near the center of the extrusion mold is approximately parallel to the axial
direction of the extrusion mold. In the steady plastic deformation zone, the fiber
orientation is relatively uniform and close to be parallel to the axial direction of the
extrusion mold except for the bottom region, in which the fiber orientation is
relatively random. In the dead deformation zone the fiber orientation maintains the
approximately random distribution.
According to the fiber orientation distribution and the directions of the principal
strains, the schematic fiber orientation of some special sample points (Figure 14) in
the extruded Csf/Mg composites is given, regarding that the fiber orientation in the
cross section are considered of the extruded Csf/Mg composites product while the
those in the circumference circumferential direction are neglected.
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Fig.13 Three deformation regions in the extruded Csf/Mg composites
Fig.14 Diagrammatic sketch of the fiber orientation distribution at some sample points
5. Conclusion
In this articlework, the principal strain driveninduced fiber orientation evolution
mechanism is proposed, which states that the fiber orientation evolution of fibers in
the Csf/Mg composites with a large deformation is determined by the principal
strains. The fiber orientation factors iF areis proposed to characterize the fiber
orientation distribution in the extruded Csf/Mg composites, which is a function of
the principal strains. Through tThe fiber orientation factors s
iF predicted by the FE
simulations coinciding well with those m
iF measured from the micrographs of the
extrusion experiments demonstrates the validity of the principal strain
driveninduced fiber orientation evolution mechanism is verified.
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The fiber orientation evolution in the Csf/Mg composites during the extrusion
forming process is investigated. and findThe results show that the fibers are
reoriented towards the direction of the maximum principal strain and deviated
from the direction of the minimum principal strain, while the fiber orientation
degree of fibers along the direction of the mediumintermediate principal strain
ranges between that those along the directions of the maximum and minimum
principal strains.
Acknowledgements
The work presented here was financially supported by the National Nature Science
Foundation of China (No. 51275417 and No. 51221001), the Doctorate Foundation
of Northwestern Polytechnical University (CX201312) and the Short-term Oversea
Visiting Scholar Program of Gradual School at Northwestern Polytechnical
University.
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