A low-cost trans-scale model for the collaborative analysis of the manufacturing and in-service process of unidirectional CFRP composites

During the manufacturing of thermoset-based carbon fiber-reinforced polymer (CFRP) structures, a curing process involving thermal, chemical, and mechanical interactions occurs. This process gives rise to micro-scale residual stresses due to differences in fiber and resin properties, leading to decreased mechanical properties compared to nominal values. A trans-scale analysis method utilizing the reduced order model (ROM) is applied in this study to establish a connection between the manufacturing and in-service processes for unidirectional CFRP (UD-CFRP). By employing this method, the evolution of residual stresses at the micro-scale during UD-CFRP manufacturing is predicted, and the impact of these residual stresses on structural performance during service is assessed. Specifically, the manufacturing-induced residual stresses reduce the material strength by a minimum of 19.31%, while also exploring the correlation between macro-scale and micro-scale failures. Notably, the computational cost of this method is significantly lower, with a reduction factor of 103 compared to the finite element method. Empirical evidence supports the effectiveness of this method in accurately predicting outcomes throughout both the manufacturing and in-service processes.Highlights Trans-scale analysis method links composites manufacturing simulation to in-service performance. Highly efficient trans-scale method excels in cost, accuracy, consistency, and convergence. Residual stresses from the curing process significantly impact matrix safety.