Realistic finite element models of 3D woven composites are constructed utilizing micro-scale numerical modeling to accurately represent the geometry of as-woven textile fabrics. The models are used to predict microcracking of carbon fiber / epoxy composites during resin curing. Numerical predictions of the stress concentration areas correlate well with the observations of microcracking obtained by micro-computed tomography.
Finite element models of 3D woven composites are developed to predict possible microcracking of the matrix during curing. A specific ply-to-ply weave architecture for carbon fiber reinforced epoxy is chosen as a benchmark case. Two approaches to defining the geometry of reinforcement are considered. One is based on the nominal description of composite, and the second involves fabric mechanics simulations. Finite element models utilizing these approaches are used to calculate the overall elastic properties of the composite, and predict residual stresses due to resin curing. It is shown that for the same volume fraction of reinforcement, the difference in the predicted overall in-plane stiffness is on the order of 10%. Numerical model utilizing the fabric mechanics simulations predicts lower level of residual stresses due to curing, as compared to nominal geometry models.
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