Modeling and Evaluation of the Generation Stresses during the Extrusion of Copper Matrix Composite

Abstract

Composite materials provide low mass, good strength, and rigidity with high-performance products. However, combining many layers of material with different orientations by the addition of some reinforcements will enhance the material properties. Due to the nonlinear behavior of the extruded composite, the possibility of material failure will increase after generation stresses increase. The main objective of this work is to examine and determine the strength of a copper composite that is used in many applications such as aircraft and rocket motors. Due to the local discontinuity stiffeners that cause stress concentrations that impose high effects on the composite material, the analysis will be more complicated.  Moreover, the presence of buckling can propagate through the structure to cause extra failures. The requested output in this model will allow the creation of plots of the model to give an indication of which regions are carrying the highest values of stress and strain. A cylindrical specimen with a diameter of (60 mm) and a (210 mm) length is considered in this study. This method is useful if we intended to use experiments based on this analysis. However, due to the nonlinearity of the material behavior, the computational solution costs would be greater. The distribution of axial pressure along the surface area and a nonlinear load-deflection analysis is used to predict the material behavior. Consequently, the shell element (CAX4R) type with (4-node) is used.  The material orientation is defined by the relative angle of the model specification.  The transverse shear effects are significant in the analysis of composites’ cases, so the transverse shear stress along the element is calculated by using an approximation based on a numerical penalty.  However, this type of analysis is interested in many fields of the industry.