On the effectiveness of deep material networks for the multi-scale virtual characterization of short fiber-reinforced thermoplastics under highly nonlinear load cases

Abstract A key challenge for the virtual characterization of components manufactured using short fiber-reinforced thermoplastics (SFRTs) is the inherent anisotropy which stems from the manufacturing process. To address this, a multi-scale approach is necessary, leveraging deep material networks (DMNs) as a micromechanical surrogate, for a one-stop solution when simulating SFRTs under highly nonlinear long-term load cases like creep and fatigue. Therefore, we extend the a priori fiber orientation tensor interpolation for quasi-static loading (Liu et al. in Intelligent multi-scale simulation based on process-guided composite database. arXiv:2003.09491 , 2020; Gajek et al. in Comput Methods Appl Mech Eng 384:113,952, 2021; Meyer et al. in Compos Part B Eng 110,380, 2022) using DMNs with a posteriori approach. We also use the trained DMN framework to simulate the stiffness degradation under fatigue loading with a linear fatigue-damage law for the matrix. We evaluate the effectiveness of the interpolation approach for a variety of load classes using a dedicated fully coupled plasticity and creep model for the polymer matrix. The proposed methodology is validated through comparison with composite experiments, revealing the limitations of the linear fatigue-damage law. Therefore, we introduce a new power-law fatigue-damage model for the matrix in the micro-scale, leveraging the quasi-model-free nature of the DMN, i.e., it models the microstructure independent of the material models attached to the constituents of the microstructure. The DMN framework is shown to effectively extend material models and inversely identify model parameters based on composite experiments for all possible orientation states and variety of material models.