An integrated microstructure reconstruction and meshing framework for finite element modeling of woven fiber-composites

• DOI: 10.1016/j.cma.2024.116797
• Publication Date: 2024-02-08T11:16:12Z
• Authors: Pengfei Zhang; Salil Pai; Jack S. Turicek; Alexander D. Snyder; Jason F. Patrick; Soheil Soghrati
• Keywords: Woven fabric; Weaving; Adaptive Mesh Refinement

Critical to finite element (FE) analysis of fiber-reinforced composites is accurately reproducing microstructural features via high-quality meshes such that the material heterogeneity and anisotropy are properly captured. Here we present an integrated computational framework for generating realistic FE models woven with high fiber volume fractions (>50%). This relies on a virtual microstructure reconstruction algorithm first generates geometric model loosely-woven yarns (i.e., bundles fibers), followed by performing compaction simulation create final textile composite microstructure. A non-iterative meshing algorithm, i.e., conforming interface structured adaptive mesh refinement (CISAMR), has been adapted automatically transform synthesized microstructures into meshes. CISAMR can handle challenging geometrical as thin resin interstices yarn interpenetrations (an artifact compaction) without need reprocess digital geometry before generation. We show homogenized elastic moduli obtained from simulations 8-harness satin laminate agree well experimental measurements (within 3%), thereby validating accuracy framework. also several other mechanical examples, including nonlinear damage simulation, further demonstrate ability this construct high-fidelity intricate varying 2D 3D architectures.