Meso-scale Finite Element (FE) modelling of biaxial carbon fibre non-crimp-fabric (NCF) based composites under uniaxial tension and in-plane shear

Non-crimp-fabrics (NCF) are promising materials in aerospace applications. The complex internal structure of NCF composites could influence the in-plane performances, which needs to be comprehensively studied. The novel three-dimensional (3D) meso-scale repeated unit cell (RUC) models were proposed for biaxial NCF composites based on the Finite Element (FE) method to conduct a systematic parameter study, including layup sequence, out-of-plane tow waviness, resin-rich areas, transverse tow placements and delamination. The meso RUC model could effectively predict the homogenised uniaxial tensile and in-plane shear properties of biaxial NCF composites based on their meso-scale constituent and material properties. A multiscale framework was also developed for biaxial NCF composites. A micromechanical representative volume element (RVE) model provided homogenised mechanical properties for tows, and a macroscopical FE model validated the test results using the homogenised results obtained from meso RUC models. The numerical results were in good agreement with the experiment results. Therefore, the multiscale framework provides an insight into the critical parameters influencing the in-plane properties of NCF composites and an analysis tool for NCF material design.