An Integrated Multiscale Simulation Routine to Predict Mechanical Performance from Manufacturing Effects

Structural performance of unidirectional composites (UD) is directly dependent on its ingredient’s properties, ply configurations and the manufacturing effects. Prediction of mechanical properties using multiscale manufacturing simulation and micromechanical models is the focus of this study. Particular problem of coupled dual-scale deformation-flow process such as the one arising in RTM, Vacuum-Assisted Resin Infusion (VARI) and Vacuum Bag Only (VBO) prepregs is considered. A finite element formulation of porous media theory framework is employed to predict the element-wise local volume fractions and the deformation of a preform in a press forming process. This formulation considers coupling effects between macro-scale preform processes and mesoscale ply processes as well as coupling effects between the solid and fluid phases. A number of different micromechanical models are assessed and the most suitable one is used to calculate mechanical properties from volume fractions. Structural performance of the “deformed” geometry is then evaluated in mechanical analysis. An integrated platform is designed to cover the whole chain of analysis and perform the properties’ calculation and transfer them between the modules in a smooth mapping procedure. The paper is concluded with a numerical example, where a compression-relaxation test of a planar fluid filled prepreg at globally un-drained condition is considered followed by a mechanical loading analysis. The development is user friendly and interactive and is established to enable design and optimization of composites.