A two‐scale numerical analysis of intra‐yarn hybrid natural/synthetic woven composites

Abstract This paper investigates how combining natural and synthetic fibers within yarns, altering the degree of hybridisation, and varying weave architectures affect the homogenized elastic properties and stress distributions in 2D woven composite laminae using a two‐scale homogenization scheme. The novelty lies in integrating a micro‐scale representative volume element model with a meso‐scale repeating unit cell model to capture intra‐yarn natural/synthetic fiber hybridisation. The study focuses on 2/2 twill and 5‐harness satin woven laminae with flax/E‐glass, hemp/E‐glass and basalt/E‐glass hybrid yarns, all with a total fiber volume fraction of 0.6. Fiber distributions are created through a random sequential expansion algorithm for hybrid RVEs, while periodic meso‐structures are used to define weave architectures for RUCs. Results show that yarn‐level fiber hybridisation significantly influences matrix stress distributions, with variations of up to 22%. In contrast, weave architecture has a minimal effect, with variations in homogenized properties below 2%. Varying fiber types, degrees of hybridisation and weave architectures allow for the tailoring of yarn and lamina properties and altering the stress distributions at micro‐ and meso‐scales and potentially influencing damage mechanisms. The modeling approach for analyzing the mechanical behavior of intra‐yarn hybrid natural/synthetic woven laminae could potentially be used to tailor their tolerance to damage. Highlights Two‐scale homogenization integrates RVE and RUC for 2D woven hybrid composites. Analyzed flax/E‐glass, hemp/E‐glass, basalt/E‐glass in twill and satin weaves. Intra‐yarn hybridisation significantly affects properties and stress fields. Hybridizing fibers offers tailored properties and may improve damage tolerance.