A multi-scale analysis to predict elastic response in different weight fractions of carbon fiber powder

In this study, the effect of varying weight percentages of carbon fiber powder (CFP) (10 wt.%, 20 wt.% and 30 wt.%) on the mechanical properties of polycarbonate (PC) components produced by plastic injection molding was investigated using analytical, numerical and experimental methods. This research is a novel study in terms of comparing experimental data with microscopic features and full-scale analysis. The micro-scale study was carried out using the Halpin-Tsai (HT) and Generalized Modified Halpin Tsai (G-HT) models as well as the representative volume element (RVE). Findings from RVE were then transferred to the finite element analysis (FEA) module for full-scale comprehensive analysis. A comparison of the experimental tensile test results demonstrated an increase of 56.90% and 191.47% in the tensile strength and Young’s modulus of the composite containing 30 wt. % CFP compared to pure PC, respectively. The minimum and maximum differences between Young’s modulus and the experimental Young’s modulus were determined to be 0.39% and 7.92% using RVE and G-HT, respectively. The maximum and minimum value of the difference between experimental and FEA strengths were determined as 3.44% and 1.91%, respectively. Young’s modulus of the composite with increasing fiber weight ratio was successfully predicted by RVE, G-HT and FEA.