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

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