A 3D finite element model to simulate progressive damage in unidirectional- and woven-fibre thermoplastic discontinuous-long-fibre composites

Discontinuous-long-fibre (DLF) composites fabricated from pre-impregnated unidirectional (UD) fibre chips are susceptible to structural deficiency. The in-plane highly anisotropic mechanical properties of the chips combined with the random nature of fibre orientation causes local weaknesses within the material when fibres are perpendicular to the load. Recent experimental results have shown that using woven-fibre chips could improve the performance of DLF composites by increasing their average mechanical properties and reducing their variability. To better understand the underlying phenomenon giving an advantage to the woven chips, a finite element model was developed to predict the mechanical properties obtained from a standard tensile test. DLF chips were modelled based on a voxel method where random chip positions were generated by an algorithm developed in this work. ANSYS® software was utilized to model the non-linear response associated with progressive damage of the composite. The maximum stress and the Puck failure criteria were employed to define damage initiation for the woven and UD fibres, respectively. Tensile modulus predictions for both types of chips showed good results when compared to experimental data. Strength predictions for the UD fibres also showed good correlation with experimental results, but the model overestimated the strength of the woven-fibre DLF composite. It appeared that the failure of the UD-fibre composites was associated with matrix failure (transverse tension and in-plane shear). Woven-fibre composites, however, showed damage modes linked to both fibre failure (longitudinal tension) and matrix failure (transverse tension and in-plane shear).