Finite element mesh generation for composites with ply waviness based on X-ray computed tomography

A method for automated generation of finite element meshes for unidirectional composites with waviness defects is proposed. Images used as input for mesh generation are recorded with X-ray computed micro-tomography. Quality and contrast of the scanned images is such that fiber directions cannot be detected everywhere. To generate finite elements mesh that follow fiber directions it is suggested to interpolate available fiber slope data using radial basis functions and to create mesh nodes by integrating ordinary differential equations for fiber slopes. Examples demonstrate practical steps of detecting waviness from volume slice images and generation of meshes that model waviness defects with acceptable accuracy.

► Method for automated generation of finite element meshes for composites with waviness defects.
► Method is based on analysis of virtual sections of X-ray computed tomography scans.
► Waviness field is approximated by edge detection for contrast variations due to fiber content.
► Finite element mesh generated by integration of RBF interpolated gradients of waviness field.
► Method tested on unidirectional composite specimens of various geometry and materials.