Finite Element Modelling of a 3D Woven Composite for Automotive Applications

Authors: Ahmad R. Zamani, Luigi Sanguigno, Angelo R. Maligno

Abstract:

A 3D woven composite, designed for automotive applications, is studied using Abaqus Finite Element (FE) software suite. Python scripts were developed to build FE models of the woven composite in Complete Abaqus Environment (CAE). They can read TexGen or WiseTex files and automatically generate consistent meshes of the fabric and the matrix. A user menu is provided to help define parameters for the FE models, such as type and size of the elements in fabric and matrix as well as the type of matrix-fabric interaction. Node-to-node constraints were imposed to guarantee periodicity of the deformed shapes at the boundaries of the representative volume element of the composite. Tensile loads in three axes and biaxial loads in x-y directions have been applied at different Fibre Volume Fractions (FVFs). A simple damage model was implemented via an Abaqus user material (UMAT) subroutine. Existing tools for homogenization were also used, including voxel mesh generation from TexGen as well as Abaqus Micromechanics plugin. Linear relations between homogenised elastic properties and the FVFs are given. The FE models of composite exhibited balanced behaviour with respect to warp and weft directions in terms of both stiffness and strength.

Keywords: 3D woven composite, meso-scale finite element modelling, homogenisation of elastic material properties, Abaqus Python scripting.

References:

[1] M. Ansar, W. Xinwei and Z. Chouwei, "Modeling strategies of 3D woven composites: A review," Compositer Structures, vol. 93, no. 8, pp. 1947-1963, July 2011.
[2] X. Chen, L. Waterton and L.-J. Tsai, "An overview of fabrication of three-dimesional woven textile preforms for composites," Textile Research Journal, vol. 81, no. 9, 2011.
[3] N. S. Karaduman, Y. Karaduman, H. Ozdemir and G. Ozdemir, "Textile Reinforced Structural Composites for Advanced Applications," in Textiles for Advanced Applications, InTech, 2017, pp. 87-133.
[4] H. M. El-Dessouky and N. Saleh, "3D Woven Composites: From Weaving to Manufacturing," in Recent Developments in the Field of Carbon Fibers, 2017, pp. 51-66.
[5] L. Ciobanu, "Development of 3D Knitted Fabrics for Advanced Composite Materials," in Advances in Composite Materials - Ecodesign and Analysis, 2011.
[6] P. Ünal, "3D Woven Fabrics," 2012, pp. 91-120.
[7] A. P. Mouritz, M. K. Bannister, P. J. Falzon and K. H. Leong, "Review of applications for advanced three-dimensional fibre textile composites," Composites: Part A, vol. 30, p. 1445–1461, 1999.
[8] T. Gereke and C. Cherif, "A review of numerical models for 3D woven composite reinforcements," Composite Structures, vol. 209, pp. 60-66, 1 February 2019.
[9] X. Zeng, L. P. Brown, A. Endruweit, M. Matveev and A. C. Long, "Geometrical modelling of 3D woven reinforcements for polymer composites: Prediction of fabric permeability and composite mechanical properties," Composites: Part A, vol. 56, pp. 150-160, 2014.
[10] M. Sherburn, "Geometric and Mechanical Modelling of Textiles," 2007.
[11] S. V. Lomov, "WiseTex software suit," 2013.
[12] S. Dhiman, P. Polturi and C. Silva, "Influence of binder configuration on 3D woven composites," Composite Structures, vol. 134, pp. 862-868, 2015.
[13] S. Lejeunes and S. Bourgeois, "Une Toolbox Abaqus pour le calcul de propriétés effectives de milieux hétérogènes," in 10e colloque national en calcul des structures, Giens, France, 2011.
[14] S. A. Tabatabaei and S. V. Lomov, "Eliminating the volume redundancy of embedded elements and yarn interpenetrations in meso-finite element modelling of textile composites," Composite Structures, vol. 152, pp. 142-154, 2015.
[15] S. A. Tabatabaei, S. V. Lomov and I. Verpoest, "Assessment of embedded element technique in meso-FE modelling of fibre reinforced composites," Composite Structures, vol. 107, pp. 436-446, January 2014.
[16] A. Y. Matveeva, H. J. Böhm , G. Kravchenko and F. W. J. van Hattum, "Investigation of the Embedded Element Technique for Modelling Wavy CNT Composites," vol. 42, 2014.