Automating Structural Modeling of Composites Enriched by X-Ray Micro-Tomography and Digital Imaging Data

The manufacturing processes of Fiber Reinforced Polymers (FRPs) as composite materials are frequently prone to the creation of various types of undesired morphologies and defects. These can include layer waviness, inclusions, and voids. Structural modeling for Finite Element Analysis (FEA) of structures including such morphologies and defects has not been practically realizable until recent developments in X-ray microtomography enabled the detection of such defects in a nondestructive manner. In the present work we present our initial steps toward the FEA modeling of FRP composite structures that leverage utilization of X-ray and regular digital imaging data as well as semi-automated methods for generating appropriate FEA models. Emphasis is given in defining waviness-driven curvilinear coordinate systems, defect identification and integration of both waviness and defects to FEA analysis including a planestrain application of a curved composite bracket under four-point bending conditions.