A multiscale scheme for homogenization to characterize the flexural performances of injection molded short glass fiber reinforced polyether ether ketone composites

Abstract The characterization of the flexural performances of short glass fiber reinforced polyether‐ether‐ketone (SGFR‐PEEK) composites fabricated by injection molding is a crucial and challenging task due to the process‐induced fiber orientation at different locations, resulting layered shell‐core‐shell microstructures and exhibiting large variations in mechanical performances. This article proposes a method for predicting the bending performance of SGFR‐PEEK and indicates the influence of fiber orientation on its bending behavior. This article reports a new scheme that combines multiscale homogenization with periodic microstructures and presents an experimental investigation of the flexural properties of SGFR‐PEEK composites. The distributions of fiber orientation through the thickness extracted from the micro‐computed tomography (μCT) were analyzed and reproduced with a layered skin‐shell‐core structure along the thickness at meso‐scale finite element model within representative volume elements (RVEs) of the macroscopic composites. Then, the effective properties of the RVEs were predicted using the homogenization method with the periodic boundary condition. The elastic modulus of skin‐shell‐core layers in the direction of flow are 4260.51, 4541.27, 4628.52, and 4630.84 MPa, respectively. The classical laminate theory (CLT) and the second homogenization implementation were then utilized in conjunction with the obtained mechanical properties of RVEs to predict the effective macrostructural behavior. The flexural modulus of the composite material was determined to be 5448.7 MPa through a three‐point bending test. The results obtained through lamination plate reinforcement theory and finite element simulation were 5887.4 and 5785.9 MPa, respectively, showing good agreement with the experimental findings. It is shown that the proposed multiscale scheme yields satisfactory agreement with experimental measurements. In addition, the effect of layered skin‐shell‐core microstructures on the flexural behavior was discussed. Highlights RVEs of layered shell‐core‐shell microstructures were generated with specified fiber orientations. The homogenization scheme with the periodic boundary condition was adopted to accurately predict each layer mechanical properties. The proposed multiscale scheme was compared with experimental results and yielded satisfactory predictions. The effect of layered skin‐shell‐core microstructures on the flexural behavior was thoroughly studied by the multiscale analytical approach.