Direct FE ² ‐Based Multiscale Modeling of Progressive Damage in Woven Carbon Fiber Composites

ABSTRACT Woven composites exhibit complex mechanical behavior due to intricate microstructural architecture, necessitating efficient multiscale modeling strategies. This study proposes a Direct FE ² ‐based computational framework to capture the mechanical response and progressive damage evolution of carbon fiber woven composites across multiple scales. The model incorporates damage mechanisms within the matrix, fibers, and interfaces, with validation against full‐field Direct Numerical Simulation (DNS) results. Comparisons confirm excellent agreement in load–displacement behavior, deformation fields, and damage evolution. A parametric investigation examines the effects of macroscopic mesh size and Representative Volume Element (RVE) dimensions on computational cost versus predictive accuracy trade‐offs. While finer meshes and larger RVEs enhance accuracy, they increase computational expense significantly. Through optimal parameter tuning, an efficient and accurate modeling strategy is achieved. This study demonstrates that the Direct FE ² method serves as a robust, scalable, and computationally efficient alternative to full‐field simulations. It thus provides a practical and reliable computational tool for multiscale analysis of mechanical behavior and progressive damage in woven composites.