Manufacturing-induced residual stresses in carbon/epoxy 3D woven composites arise during cooling after curing due to a large difference in the coefficients of thermal expansion between the carbon fibers and the epoxy matrix. The magnitudes of these stresses appear to be higher in composites with high throughthickness reinforcement and in some cases are sufficient to lead to matrix cracking. This paper presents a numerical approach to simulation of development of manufacturing-induced residual stresses in an orthogonal 3D woven composite unit cell using finite element analysis. The proposed mesoscale modeling combines viscoelastic stress relaxation of the epoxy matrix and realistic reinforcement geometry (based on microtomography and fabric mechanics simulations) and includes imaginginformed interfacial (tow/matrix) cracks. Sensitivity of the numerical predictions to reinforcement geometry and presence of defects is discussed. To validate the predictions, blind hole drilling is simulated, and the predicted resulting surface displacements are compared to the experimentally measured values. The validated model provides an insight into the volumetric distribution of residual stresses in 3D woven composites. The presented approach can be used for studies of residual stress effects on mechanical performance of composites and strategies directed at their mitigation.
EFFECT OF MATRIX VISCOELASTICITY ON PREDICTION OF RESIDUAL STRESSES IN ORTHOGONAL 3D WOVEN COMPOSITES
In this paper, the effect of matrix viscoelasticity on the development of residual stresses
in 3D woven composites is investigated using Finite Element Analysis. Based on
experimental observations, it is hypothesized, that the stresses develop mainly due to the
difference in the coefficients of thermal expansion between the fiber reinforcement and
the matrix. The model considered is a “1x1 orthogonal” 3D woven composite unit cell that
is generated using x-ray computed microtomography data. In this study, cooling after
curing is considered under the assumption of zero stress at the beginning of the cooling.
In addition to the full time- and temperature-dependent viscoelastic formulation, the
applicability of two simplified constitutive methods, elastic and variable time pseudoviscoelastic,
is investigated. It is observed that the pseudo-viscoelastic method predicts
similar cumulative stress distribution (Von Mises and Hydrostatic) compared to the full
viscoelastic results. The elastic model presented the highest stress values while the full
viscoelastic model presented the lowest stress values.
- Award ID(s):
- 1662098
- Publication Date:
- NSF-PAR ID:
- 10105154
- Journal Name:
- Proceedings of NUMIFORM 2019: The 13th International Conference on Numerical Methods in Industrial Forming Processes
- Sponsoring Org:
- National Science Foundation
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