Evaluating Residual Stress in Carbon Fiber-Reinforced Polymer (CFRP) at Microscale Using Fiber Push-Out Experiment and Finite Element Modeling

Microscale process-induced residual stresses arising during the manufacturing of Carbon Fiber-Reinforced Polymer (CFRP) composites significantly influence their macroscopic mechanical performance. This research direction explores a data-driven methodology to characterize these localized stresses by integrating experimental fiber push-out testing with advanced numerical simulations. Utilizing in situ scanning electron microscopy (SEM), the physical phenomenon of through-thickness matrix sink-in deformation in resin-rich regions is captured following the displacement of adjacent fibers. This deformation, which serves as a physical indicator of released residual stress, is quantitatively measured. To reconstruct the stress state, a Finite Element Model Updating (FEMU) framework is established. The numerical model comprehensively simulates the composite curing cycle, specimen machining, and the

subsequent fiber push-out sequence. By correlating the simulated out-of-plane matrix deformation—often exceeding one percent of the specimen thickness—with experimental SEM observations, the microscale residual stress distribution is systematically back-calculated. This methodology provides structured guidance for validating micromechanical models, offering critical implementation support for integrated computational materials engineering (ICME) frameworks aimed at the high-fidelity design and optimization of advanced composite structures.

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