A multiscale framework for predicting the mechanical properties of unidirectional non-crimp fabric composites with manufacturing induced defects

The aim of this study was to evaluate the effect of manufacturing induced in-plane tow misalignment and out-of-plane tow crimp on the mechanical properties of a heavy-tow unidirectional non-crimp fabric (UD-NCF) composite. The elastic constants and failure onset (strength) are predicted by employing a multiscale computational approach. Micro-scale finite element (FE) models that explicitly represent the fibers and matrix within the tow microstructure were used to predict the effective properties of the tow. Meso-scale FE models comprised of the homogenized tows and surrounding matrix were used to predict the properties of a UD NCF composite lamina. Four meso-scale models, identified as ideal, crimp, misalignment and real, were considered in this study. No manufacturing defects were represented in the ideal model, while out-of-plane crimp, in-plane misalignment and both out-of-plane crimp and in-plane misalignment were accounted for in the crimp model, misalignment model and real model, respectively. Predicted lamina stiffness based on the real model are found to be in an excellent agreement with available experimental data, which was not always the case for the other three models. The longitudinal and transverse strength predictions are found to be dependent on the chosen local failure criteria for each model. Max-stress and Puck's fiber failure criteria provide an excellent estimate of longitudinal strength while the Puck's inter-fiber failure and Tsai-Hill criteria predict transverse strength with good accuracy. The feasibility to accurately predict the mechanical properties of heavy tow non-crimp fabric composites by incorporating their inherent micro-structural defects is demonstrated in this study.

Automated summary

This study evaluated the effects of manufacturing induced misalignment and crimp on heavy-tow non-crimp fabric composites, predicting properties using multiscale computational approaches. The real model showed excellent agreement with experimental data in predicting lamina stiffness, demonstrating the feasibility of accurately predicting mechanical properties by incorporating micro-structural defects.