Influence of Fiber Volume Fraction on the Predictability of UD FRP Ply Behavior: A Validated Micromechanical Virtual Testing Approach

Enhancing the understanding of the behavior, optimizing the design, and improving the predictability and reliability of manufactured unidirectional (UD) FRP plies, which serve as primary building blocks for structural FRP laminates and components, are crucial to achieving a safe and cost-effective design. This research investigated the influence of fiber volume fraction (vf) on the predictability and reliability of the homogenized elastic properties and damage initiation strengths of two different types of UD FRP plies using validated micromechanical virtual testing for representative volume element (RVE) models. Several sources of uncertainties were included in the RVE models. This study also proposed a modified algorithm for microstructure generation and explored the effect of vf on the optimal sizes of the RVE in terms of fiber number. Virtual tests were systematically conducted using full factorial DOE coupled with Monte Carlo simulation. The modified algorithm demonstrated exceptional performance in terms of convergence speed and jamming limit, significantly reducing the time required to generate microstructures. The developed RVE models accurately predicted failure modes, loci, homogenized elastic properties, and damage initiation strengths with a mean error of less than 5%. Also, it was found that increasing vf led to a concurrent increase in the optimal size of the RVE. While it was found that the vf had a direct influence on homogenized elastic properties and damage initiation strengths, it did not significantly affect the reliability and predictability of these properties, as indicated by low correlation coefficients and fluctuations in the coefficient of variation of normalized properties.