Robust numerical analysis of fibrous composites from X-ray computed tomography image data enabling low resolutions

X-ray computed tomography scans can provide detailed information about the state of the material after manufacture and in service. X-ray computed tomography aided engineering (XAE) was recently introduced as an automated process to transfer 3D image data to finite element models. The implementation of a structure tensor code for material orientation analysis in combination with a newly developed integration point-wise fibre orientation mapping allows an easy applicable, computationally cheap, fast, and accurate model set-up. The robustness of the proposed approach is demonstrated on a non-crimp fabric glass fibre reinforced composite for a low resolution case with a voxel size of 64 μm corresponding to more than three times the fibre diameter. Even though 99.8% of the original image data is removed, the simulated elastic modulus of the considered non-crimp fabric composite is only underestimated by 4.7% compared to the simulation result based on the original high resolution scan

Dataset of non-crimp fabric reinforced composites for an X-ray computer tomography aided engineering process

This data in brief article describes a dataset used for an X-ray computer tomography aided engineering process consisting of X-ray computer tomography data and finite element models of non-crimp fabric glass fibre reinforced composites. Additional scanning electron microscope images are provided for the validation of the fibre volume fraction. The specimens consist of 4 layers of unidirectional bundles each supported by off-axis backing bundles with an average orientation on \ub180\ub0. The finite element models, which were created solely on the image data, simulate the tensile stiffness of the samples. The data can be used as a benchmark dataset to apply different segmentation algorithms on the X-ray computer tomography data. It can be further used to run the models using different finite element solvers

Automated X-ray computer tomography segmentation method for finite element analysis of non-crimp fabric reinforced composites

In this study a complete procedure is presented of how to generate finite element models based on X-ray computer tomography data on the fibre bundle scale for non-crimp fabric reinforced composites. Non-crimp fabric reinforced composites are nowadays extensively used in the load carrying parts of wind turbine blades. Finite element analysis based on X-ray computer tomographic data will allow faster and cheaper developments of key material parameters. However, automated procedures for computer tomography data transfer into finite elements models are lacking. In the current study, an X-ray computer tomography aided engineering (XAE) process including a fully automated segmentation method and an element-wise material orientation mapping of X-Ray computer tomographic data is presented for the first time. The proposed methodology combines recent research progress and improvements in image analysis, and provides a fast, accurate and repeatable data transfer and analysis process with a high degree of automation

X-ray scattering tensor tomography based finite element modelling of heterogeneous materials

Among micro-scale imaging technologies of materials, X-ray micro-computed tomography has evolved as most popular choice, even though it is restricted to limited field-of-views and long acquisition times. With recent progress in small-angle X-ray scattering these downsides of conventional absorption-based computed tomography have been overcome, allowing complete analysis of the micro-architecture for samples in the dimension of centimetres in a matter of minutes. These advances have been triggered through improved X-ray optical elements and acquisition methods. However, it has not yet been shown how to effectively transfer this small-angle X-ray scattering data into a numerical model capable of accurately predicting the actual material properties. Here, a method is presented to numerically predict mechanical properties of a carbon fibre-reinforced polymer based on imaging data with a voxel-size of 100 mu m corresponding to approximately fifteen times the fibre diameter. This extremely low resolution requires a completely new way of constructing the material's constitutive law based on the fibre orientation, the X-ray scattering anisotropy, and the X-ray scattering intensity. The proposed method combining the advances in X-ray imaging and the presented material model opens for an accurate tensile modulus prediction for volumes of interest between three to six orders of magnitude larger than those conventional carbon fibre orientation image-based models can cover.ISSN:2057-396

Structure tensor analysis and 2D finite element integration pointwise material orientation mapping

The mapping of the 2D projection of the material orientation into a finite element model (Abaqus). Jupyter Notebook will perform a structure tensor analysis of an x-ray scan and extract the values in the integration points of a finite element model. The scan-data should be loaded as a nifti-file and the finite element integration points should be present in a by Abaqus generated dat-file. The output will be a Fortran file for each mapped slice which then can be used as a "INCLUDE" fortran file in the orient.f user-subroutine inside Abaqus

Automated X-ray computer tomography segmentation method for finite element analysis of non-crimp fabrics reinforced composites

Data behind the publications: Auenhammer, R.M., Mikkelsen, L.P., Asp, L., Blinzler, B. Automated X-ray computer tomography segmentation method for finite element analysis of non-crimp fabric reinforced composites. Composite Structures, 256, 113136, https://doi.org/10.1016/j.compstruct.2020.113136, 2021. Auenhammer, Robert M., Lars P. Mikkelsen, Leif E. Asp, Brina J. Blinzler, Dataset of non-crimp fabric reinforced composites for an X-ray computer tomography aided engineering process, Data in Brief, 33, 106518, https://doi.org/10.1016/j.dib.2020.106518, 2020. Auenhammer, R.M., L.P. Mikkelsen, L.E. Asp, B.J. Blinzler, X-ray tomography based numerical analysis of stress concentrations in non-crimp fabric reinforced composites - assessment of segmentation methods. IOP Conf. Ser.: Mater. Sci. Eng. 942, 012038, https://doi.org/10.1088/1757-899X/942/1/012038, 2020 The data-set contain data from three samples: A, E and G. For each sample the data are saved in the follow format X-ray scan: nii-files SEM scan: tif-files Abaqus files: inp-files X-ray setting: pdf-files SEM settings: hdr-ascii file