Mesh morphing methodology for strength predictions in composites

This work presents a methodology based on mesh morphing techniques for transfer of high-fidelity X-ray computed tomography (CT) data, including manufacturing defects information, into finite element (FE) models for failure prognosis in composite structures. An IM7/8552 carbon/epoxy hat-section element with complex layup is considered. Failure initiates at the location of seeded defects, including in-plane and out-of-plane fiber waviness, representative of irregularities that could occur during manufacturing of composite parts with complex layup and geometry. The ability of the method to efficiently transition high fidelity CT data into structural models for assessment of the effects of manufacturing defects is essential for condition-based structural substantiation. Stress-based failure criteria are considered for prediction of matrix-dominated failure under quasi-static loading. FE results are compared with experimental data, including correlation with CT-based post-failure damage information.