Process-induced residual stress in a single carbon fiber semicrystalline polypropylene thin film

During the processing of semicrystalline thermoplastic composites, various models for the prediction of residual stress have been proposed but experimental validation is limited. In this study, a modeling framework is developed to predict the evolution of residual stress in a single carbon fiber embedded in a semicrystalline polypropylene thin film subjected to non-isothermal cooling. Validation is based on in-situ measurement of axial fiber strain after processing using micro-Raman Spectroscopy. A material model for polypropylene (50% equilibrium crystallinity) is presented that incorporates the effects of non-isothermal cooling on crystallinitydependent resin shrinkage and crystallinity-dependent resin modulus from the amorphous polymer melt to room temperature. The evolution of residual stress is calculated using a finite element (FE) model with a userdeveloped subroutine incorporating the resin material models. Single-fiber polypropylene films are fabricated using a range of fiber pretension levels to prevent fiber waviness during cooling and to induce a wide range of axial strain levels in the fiber for model validation. The fiber axial strain was measured over the length of the fiber, from the free edge into the bulk, capturing the ineffective length region where strain builds up and plateaus. A good correlation has been obtained between the model results and the in-situ measurements of axial compression strain in the fiber. A key finding was the importance of including temperature-dependent resin modulus and that the contribution of crystallinity shrinkage to residual strain in the carbon fiber is relatively low. The model developed in this study is also compared to residual stress models in the literature which shows the importance of including the effects of crystallization and cooling rate on temperature and crystallinity-dependent modulus and resin shrinkage for accurate predictions.