Multiscale damage modelling of notched and un-notched 3D woven composites with randomly distributed manufacturing defects

This work proposes a stochastic multiscale computational framework for damage modelling in 3D woven composite laminates, by considering the random distribution of manufacturing-induced imperfections. The proposed method is demonstrated to be accurate, while being simple to implement and requiring modest computational resources. In this approach, a limited number of cross-sectional views obtained from micro-computed tomography (µCT) are used to obtain the stochastic distribution of two key manufacturing-induced defects, namely waviness and voids. This distribution is fed into a multiscale progressive damage model to predict the damage response of three-dimensional (3D) orthogonal woven composites. The accuracy of the proposed model was demonstrated by performing a series of finite element simulations of the un-notched and notched tensile tests (having two different hole sizes) for resin-infused thermoplastic (Elium®) 3D woven composites. Excellent correlation was achieved between experiments and the stochastic finite element simulations. This demonstrates the effectiveness of the proposed stochastic multiscale model. The model successfully captured the stochastic nature of tensile responses (ultimate tensile strength and stiffness), damage modes (matrix damage and fibre failure), and initiation and propagation of transverse cracks in thermoplastic 3D woven composites, consistent with experimental observation. The stochastic computational framework presented in this paper can be used to guide the design and optimization of 3D textile composite structures. © 2023 The Authors