A Review on the Mechanical Modeling of Composite Manufacturing Processes

© 2016, The Author(s). The increased usage of fiber reinforced polymer composites in load bearing applications requires a detailed understanding of the process induced residual stresses and their effect on the shape distortions. This is utmost necessary in order to have more reliable composite manufacturing since the residual stresses alter the internal stress level of the composite part during the service life and the residual shape distortions may lead to not meeting the desired geometrical tolerances. The occurrence of residual stresses during the manufacturing process inherently contains diverse interactions between the involved physical phenomena mainly related to material flow, heat transfer and polymerization or crystallization. Development of numerical process models is required for virtual design and optimization of the composite manufacturing process which avoids the expensive trial-and-error based approaches. The process models as well as applications focusing on the prediction of residual stresses and shape distortions taking place in composite manufacturing are discussed in this study. The applications on both thermoset and thermoplastic based composites are reviewed in detail

Strength prediction for bi-axial braided composites by a multi-scale modelling approach

The final publication is available at Springer via http://dx.doi.org/10.1007/s10853-016-9901-z.Braided textile-reinforced composites have become increasingly attractive as protection materials thanks to their unique inter-weaving structures and excellent energy-absorption capacity. However, development of adequate models for simulation of failure processes in them remains a challenge. In this study, tensile strength and progressive damage behaviour of braided textile composites are predicted by a multi-scale modelling approach. First, a micro-scale model with hexagonal arrays of fibres was built to compute effective elastic constants and yarn strength under different loading conditions. Instead of using cited values, the input data for this micro-scale model were obtained experimentally. Subsequently, the results generated by this model were used as input for a meso-scale model. At meso-scale, Hashin’s 3D with Stassi’s failure criteria and a modified Murakami-type stiffness-degradation scheme was employed in a user-defined subroutine developed in the general-purpose finite-element software Abaqus/Standard. An overall stress–strain curve of a meso-scale representative unit cell was verified with the experimental data. Numerical studies show that bias yarns suffer continuous damage during an axial tension test. The magnitudes of ultimate strengths and Young’s moduli of the studied braided composites decreased with an increase in the braiding angle