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Paper:

Progressive Failure Prediction of Woven Fabric C


omposites Using a Multi-Scale Approach

Sung Ha, Lei Xu*


HSCL, Dept. of Mech. Eng., Hanyang

University

Structures and Composites Laboratory

Woven Fabrics
Definition
Repeat

Woven fabrics are produced by the interlacing of warp


fiber tows (0) and fill fiber tows (90) in a regular
pattern or weave style.

Advantages

Top view

Integral structures design


Easier manipulation
Better drapability and pliability
Damage tolerance, notch
insensitivity

Repeat

y
x

Terminologies
1

n
m

1 inch

n m Fabric

Side view
z

Where n number of ends (warp tows)


per inch
m number of picks (fill tows)
per inch

Warp tow

Fill tow

Ref.: http://www.netcomposites.com/guide/woven-fabrics/40

2013.3.20

Structures and Composites Laboratory

Weave Pattern of Woven Fabrics (1/4)


The weave describes how the warp and fill tows are interlaced. The most popular
weaves are plain, twill, harness satin, and crow-foot satin. Weave determines
drapability and isotropy of strength.

Plain weave
The plain weave is made by interlacing
the warp and fill tows in an alternating
pattern. The resulting pattern is flat and
smooth.

Basket weave
two or more tows are treated as one tow
when interwoven.
The basket weave is more pliable, flatter
and stronger than the plain weave, but is
not as stable.
Ref.: http://www.netcomposites.com/guide/woven-fabrics/40

2013.3.21

Structures and Composites Laboratory

Different Weaves of Woven Fabrics (2/4)


Twill weave
One or more warp tows alternately weave over or under two
or more fill tows. The weave pattern is characterized by a
straight or broken diagonal 'rib' to the fabric
Advantages:
More pliable and drapable than plain-weave or basket-weave
but not as pliable as satin.

1/1 Twill

Over or
under at
least 2 fill
tows

Satin weave, 4-harness satin

Warp tows alternatively


weave over and under

The harness number used in the designation (typically 4, 5


and 8) is the total number of fibers crossed and passed under,
before the fiber repeats the pattern.

Fill tow
no.

4-harness satin weave (crow-foot weave)

x-direction: a fill tow floats over (under) 3 warp tows and under (over) 1.
y-direction: a warp tow floats under (over) 3 fill tows and over (under) 1.
Set a sequence of fill tows first, Count the number of the fill tow which
is crossed over by the warp tow from the left to the right within a y
period.
x

1 2 4 3

2/2 Twill

4
3
2
1
1 2 4 3

Ref.: http://www.netcomposites.com/guide/woven-fabrics/40

2013.3.21

Structures and Composites Laboratory

Weave Pattern of Woven Fabrics (3/4)


Fill tow no.

Satin weave, 5-harness satin (crow-foot weave)


x-direction: a fill tow floats over (under) 4 warp tows and under (over) 1.
y-direction: a warp tow floats under (over) 4 fill tows and over (under) 1.

5
4
3

1 4 2 5 3

2
1

y
x

1 4 2 5 3

Fill tow no.

Satin weave, 7-harness satin (crow-foot weave)

7
6

x-direction: a fill tow floats over (under) 6 warp tows and under (over) 1.
y-direction: a warp tow floats under (over) 6 fill tows and over (under) 1.

5
4
3

1 5 2 6 3 7 4

2
1

y
x

1 5 2 6 3 7 4

Ref.: http://www.netcomposites.com/guide/woven-fabrics/40

2013.3.25

Structures and Composites Laboratory

Weave Pattern of Woven Fabrics (4/4)


Fill tow no.

Satin weave, 8-harness satin weave

8
7

x-direction: a fill tow floats over (under) 7 warp tows and under (over) 1.
y-direction: a warp tow floats under (over) 7 fill tows and over (under) 1.

6
5

1 4 7 2 5 8 3 6

4
3
2

Special Satin weave, 4-harness satin weave


x-direction: a fill tow floats over (under) 3 warp tows and under (over) 1.
y-direction: a warp tow floats under (over) 3 fill tows and over (under) 1.

1 3 4 2

4
3
2
1

Ref.: http://www.netcomposites.com/guide/woven-fabrics/40

2013.3.25

Structures and Composites Laboratory

Parameterization of Woven Fabrics


Woven fabrics
Plain weave and etc.

Parameters:

Twill weave

n number of parallel tows


E.g., 1 plain weave (the above picture)
2 basket weave

Parameters:

nm

Parameters:

n number of fill tows to pass over


m number of fill tows to pass under
E.g., 14 (the above picture)

1. Cross-sectional parameters of the tow:


Geometric
parameters:

Satin weave

n harness

n number of harnesses (4,5,7,8)


E.g., 8 (the above picture)

w
t

2. Undulation parameters of the tow:

Gap
Undulation

3. Gap between the adjacent tows:


2013.3.26

Structures and Composites Laboratory

Woven Fabric Modeling


(a)
w
t

(a)

2013.3.26

(b)

Structures and Composites Laboratory

Examples of Woven Fabric Modeling, Top View


Warp (Fill) tow: 1.6, 0.2 width, thickness

Plain weave and etc.

Woven fabrics

Warp (Fill) tow: 0.105, 0.05 amplitude, gap

Twill weave

Satin weave

n 1

n 2, m 1

n 4 (Crow-foot)

n2

n 2, m 2

n5

n5

n 6, m 2

n8

2013.3.29

Structures and Composites Laboratory

Examples of Woven Fabric Modeling, Top View


(a) Plain weave

(b) Twill weave

(a) Complete unit cell

2013.3.29

(b) Tows

10

(c) Satin weave

(c) Pure matrix

Structures and Composites Laboratory

2-4(3). Damage homogenization for matrix

local volume: dV

local damage: Dm

(a)

: Fiber
: Matrix damage

(c)

(b)

: Matrix

(e)

: Intact matrix

: Maximum matrix damage

11

: Homogenized matrix damage

Structures and Composites Laboratory

( n ) ( n 1) ( n )
Tow

(i)

MMF

( n ,i )
t

n 1,i

Ct

Pure matrix

( n ,i )

(q)

Micromechanical model
SAF for constituents: Mc
(c = fiber, matrix)
j

m n , q Cm n 1,q m n ,q

n ,i

c Mc t

(j)

kc f c c , Tc , Cc
j

Dc f kc , c
j

Dc

n ,i

Ec

n ,i

1 Dc

n ,i

n 1,i

n ,q

, Tm , Cm

Dm f k m , m
q

Max Dc , Dc

km f m m

Dc f Dc , p

intact
c

Update Effective stiffness using

Dm

n ,q

Em

n ,q

Max Dm , Dm

n ,q

1 Dm

n,q

n 1, q

intact
m

Structures and Composites Laboratory

x3

x3

z
y

x
x2
x2

x1
(a)

(b)

(c)

x3

x3

x2

x2

x1
(a)

(b)

13

(c)

Structures and Composites Laboratory

Examples of Woven Fabric Modeling, Bottom View


Warp tow: 1.6, 0.2 width, thickness

Woven fabrics

Fill tow: 0.8, 0.2

Plain weave and etc.

Warp (Fill) tow: 0.105, 0.05 amplitude, gap

Twill weave

Satin weave

n 1

n 3, m 1

n 4 (Crow-foot)

n2

n 3, m 3

n5

n5

n 6, m 2

n8

2013.3.29

14

Structures and Composites Laboratory

Glass Fabric 1543: Special 4-Harness Satin Weave

0.21mm

15

Structures and Composites Laboratory

Preliminary Fatigue Life Prediction of DSO


Materials

Structures
and
Composites
Laboratory
Structures
and
Composites
Laboratory

Modeling DSO composites using UFM


Modeling two types of woven fabrics

Measure geometric fabric parameters.

Characterize the resin properties (stress-strain curves, S-N curves)

Use the UFM tools

Predict the static behavior with progressive damage propagation;


Predict the Fatigue life: generation of S-N curves
Plain weave (T300/Resin)

Satin weave (E-Glass/Resin)

17

Structures and Composites Laboratory

Static & Fatigue Prediction of plain-weave fabric


s

Plain weave

18

Structures and Composites Laboratory

Modeling of plain weave fabric


Modeling
Warp tow

ABAQUS

Fill tow

1.6mm

Observation:

Average yarn width ~1.6 mm


Average gap between two adjacent yarns ~0.4 mm
Average thickness (warp + fill) ~0.28 mm
Warp and fill yarns appear flat and straight with slight
variation in width when free from external loading

0.28mm

19

Structures and Composites Laboratory

Modeling of plain weave fabric


Modeling

1.6mm

Modeling

0.28mm

Observation:

Average yarn width ~1.6 mm


Average gap between two adjacent yarns ~0.4 mm
Average thickness (warp + fill) ~0.28 mm
Warp and fill yarns appear flat and straight with slight
variation in width when free from external loading
20

Structures and Composites Laboratory

21

Structures and Composites Laboratory

Material properties of plain weave fabric


Material properties
Material properties

Fiber (T300)

Material properties

Matrix

Longitudinal modulus Ef1 (GPa)

230

Elastic modulus Em (GPa)

3.34

Transverse modulus Ef2 (GPa)

19

Elastic Poissons ratio vm

0.35

In-plane shear modulus Gf12 (GPa)

27

Transverse modulus Gf23 (GPa)

Major Poissons ratio vf12

0.3

Major Poissons ratio vf23

0.8

Tensile strength Tf (MPa)

3500

Compressive strength Cf (MPa)

2000

A of S-N curve

-0.104

B of S-N curve

1.74

Effective Material Properties

A of S-N curve

-0.0822

B of S-N curve

3.548

Material properties

Volume fractions

Tow

Longitudinal modulus Ef1 (GPa)

179.93

Transverse modulus Ef2 (GPa)

11.782

In-plane shear modulus Gf12 (GPa)

7.646

Fiber volume fraction of tow Vf_t

0.78

Transverse modulus Gf23 (GPa)

4.202

Warp Tow volume fraction of unit cell Vw

0.315

Major Poissons ratio vf12

0.228

Fiber volume fraction in warp direction


Vf_w=Vf_t Vw

0.246

Major Poissons ratio vf23

0.427

22

Structures and Composites Laboratory

Stress-strain curve prediction of plain weave fabric


Damage models
Matrix damage models
Hardening behavior
(MPa)

eq

Softening behavior

,
2

yN 1

0
y

Test data

2
y

Multi-stage model

Stage 2
Stage 1

,
1

1
y

Linearization

Stage N

E0

1 D E0
N , 0

1 y 2 y

N 1 y

N y
eq

(%)

23

Structures and Composites Laboratory

Stress-strain curve prediction of plain weave fabric


Damage models

Loading
Tows

Fiber damage models

Pure Matrix

11
11y

0.015

11
11y
24

Structures and Composites Laboratory

Stress-strain curve prediction of plain weave fabric


Stress-strain prediction
3 damage types
1. Pure matrix damage:
2. Matrix damage in tow:
3. Fiber damage in tow:

Dm

X ROM T f V f _ w 861MPa

Due to the fiber undulation and matrix, strength


prediction of FEM is lower than the value from rule of
mixture.

Dm
Df

(MPa)

X 554 MPa

Strength
predictions:

Dm

Dm

EROM E f V f _ w 56.58GPa
Df

E 53.7GPa
(%)

25

Structures and Composites Laboratory

Stress-strain curve prediction of plain weave fabric

Dm

Df

Dm

(MPa)
600
500
A
400
300
B
200
100
0

0.5

1.5

2.5

(%)
26

Structures and Composites Laboratory

Stress-strain curve prediction of plain weave fabric

(MPa)

600

Dm

500
A

400
300

Dm

200
100
0

Df
0

0.5

1.5

2.5

(%)

27

Structures and Composites Laboratory

Fatigue prediction of plain weave fabric


Loading

Life distribution
Life of pure matrix

Life of matrix in tow

Life of fiber in tow

Shortest life

Longest life

max 150MPa

Fatigue R 0.1

Under the given fatigue load, the matrix in the warp tow has the shortest life, while the
fiber in the warp tow has the longest life. Because the warp tow is under locally transverse
load and matrix can easily break.
28

Structures and Composites Laboratory

Fatigue prediction of plain weave fabric


Damage distribution

S-N Curve prediction

Number of cycles: n 1

Dm

max

amp

min
0.1
max
mean

min

t
Tension-tension (T-T)

Fiber S-N Curve

Vf_w=0.246
X=554Mpa

max ( MPa )

Dm

Fiber failure
Initial pure matrix failure
Initial matrix failure in tow

Df

LogN f
29

Structures and Composites Laboratory

Static & Fatigue Prediction of 4-harness satin wo


ven fabrics

Satin weave

30

Structures and Composites Laboratory

Modeling of 4-harness satin weave fabric


Modeling

Thickness ratio 6:1

ABAQUS
0.45mm

0.85mm

Observation:
Average yarn width ~0.45 mm
Irregular 4H Satin weave, average gap between every 2 fill yarns ~0.8
mm
No visible gap between two adjacent warp yarns
Thickness: 0.18 mm (warp), 0.03 mm (fill)
Warp yarns appear flat but slack when free from external loading, while
fill yarns seem tightening corresponding warp yarns
31

0.21mm

Structures and Composites Laboratory

Modeling of plain weave fabric


Modeling

1.6mm

Modeling

0.28mm

Observation:

Average yarn width ~1.6 mm


Average gap between two adjacent yarns ~0.4 mm
Average thickness (warp + fill) ~0.28 mm
Warp and fill yarns appear flat and straight with slight
variation in width when free from external loading
32

Structures and Composites Laboratory

Modeling of 4-harness satin weave fabric


Modeling

0.45mm

0.85mm

Modeling

Thickness ratio 6:1

0.21mm

33

Structures and Composites Laboratory

34

Structures and Composites Laboratory

Material properties of 4-harness satin weave fabric


Material properties
Material properties

Fiber (E-Glass)

Material properties

Matrix

Longitudinal modulus Ef1 (GPa)

74

Elastic modulus Em (GPa)

3.34

Transverse modulus Ef2 (GPa)

74

Elastic Poissons ratio vm

0.35

In-plane shear modulus Gf12 (GPa)

30.8

Transverse modulus Gf23 (GPa)

30.8

Major Poissons ratio vf12

0.2

Major Poissons ratio vf23

0.2

Tensile strength Tf (MPa)

1814

Compressive strength Cf (MPa)

1614

A of S-N curve

-0.163

B of S-N curve

3.45

-0.104

B of S-N curve

1.74

Effective Material Properties

Volume fractions
Fiber volume fraction of tow Vf_t

0.78

Warp Tow volume fraction of unit cell Vw

0.54

Fiber volume fraction in weft direction


Vf_w=Vf_t Vw

A of S-N curve

Material properties

Tow

Longitudinal modulus Ef1 (GPa)

42.18

Transverse modulus Ef2 (GPa)

12.61

In-plane shear modulus Gf12 (GPa)

3.792

Transverse modulus Gf23 (GPa)

3.616

Major Poissons ratio vf12

0.259

Major Poissons ratio vf23

0.419

0.42

35

Structures and Composites Laboratory

Stress-strain curve prediction of satin weave fabric


Damage models

Loading

Matrix damage models

Fiber damage models

11

(MPa)
Test data
Multi-stage model

11y

11
11y

(%)

0.03
36

Structures and Composites Laboratory

Material properties of 4-harness satin weave fabric


Stress-strain prediction
3 damage types
1. Pure matrix damage:
2. Matrix damage in tow:
3. Fiber damage in tow:

X 545MPa

Strength
predictions:
Dm

X ROM T f V f _ w 762MPa

Due to the fiber undulation and matrix, strength


prediction of FEM is lower than the value from rule of
mixture.

Dm
Df

(MPa)

Dm

Dm

E 32.98GPa

EROM E f V f _ w 31.08GPa

B
Df

(%)

37

Structures and Composites Laboratory

A
Dm

(MPa)

Dm

600
A

500

Df

400
300

B
B

200

Dm

100
0

0.5

1.5
(%)

2.5

Dm

Df
38

Structures and Composites Laboratory

Stress-strain curve prediction of plain weave fabric

(MPa)

600

Dm

500
A

400
300

Dm

200
100
0

Df
0

0.5

1.5

2.5

(%)

39

Structures and Composites Laboratory

Fatigue prediction of satin weave fabric


Loading

Life distribution
Life of pure matrix

Life of matrix in tow

LogNf

Life of fiber in tow

Shortest life

Longest life

max 70MPa

Fatigue R 0.1

Under the given fatigue load, the matrix in the warp tow has the shortest life, while the
fiber in the warp tow has the longest life. Because the warp tow is under locally transverse
load and matrix can easily break.
40

Structures and Composites Laboratory

Fatigue prediction of satin weave fabric


Damage distribution

S-N Curve prediction

Number of cycles: n 1

max

R
amp

min
0.1
max
mean

min

t
Tension-tension (T-T)

Fiber S-N Curve

Vf_w=0.42
X=545Mpa

max ( MPa )

Fiber failure
Initial pure matrix failure
Initial matrix failure in tow

LogN f
41

Structures and Composites Laboratory

Parametric study: Effects of stress ration


Effects of stress ratio

With increasing of stress ratio, the fatigue also


increases

max ( MPa )
R=0.8

Fatigue R 0.8
R=0.8
R=0.5
R=0.1

Fatigue R 0.5

R=0.1

Fatigue R 0.1
Tension-tension (T-T)

t
LogN f
42

Structures and Composites Laboratory

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