Novel method of mechanical alignment for chopped carbon fiber/high density polyethylene composites: Processing, modeling, and characterization

In this study, we investigated a novel method of mechanical alignment to enhance the tensile properties of chopped carbon fiber (CCF)/high-density polyethylene (HDPE) composites. By utilizing a novel extruder and take-up system based on the melt spinning technique, we successfully controlled the alignment of CCF at various thicknesses using mechanical tension. This facilitated the production of extruded profiles with controlled tensile conditions. Experimental measurements were conducted to evaluate the tensile strength and modulus of the composites. The results demonstrate the effectiveness of the proposed CCF alignment method, which involves adjusting the thickness of the extruded profiles, in controlling the mechanical properties of the composites. As a result, the ultimate tensile strength increased by 50%, and the tensile modulus increased by 130%. Additionally, we developed a numerical model that predicts the tensile modulus based on randomly generated fibers and the Mori-Tanaka model for property estimation. The fiber orientation distribution was influenced by the fiber shape and manufacturing conditions. Scanning electron microscope (SEM) images revealed that the fibers aligned more along the extrusion direction with increased draw ratio. The orientation distribution of the randomly generated fibers varied significantly based on the fiber length and draw ratio, indicating a narrowed distribution range along the extrusion direction with increased fiber length or draw ratio. These findings demonstrate that the proposed CCF alignment method, which involves changing the thickness of the extruded profiles, can effectively control the mechanical properties of the composite.