Dynamic Response and Fracture Evolution of 3D Woven CFRP Composites: Tensile Experiments and High‐Fidelity Mesoscale Simulations

ABSTRACT This paper investigates the dynamic tensile behavior of three‐dimensionally (3D) woven carbon fiber‐reinforced polymer (CFRP) composites using split Hopkinson tensile bar (SHTB) experiments and high‐fidelity mesoscale simulations. SHTB experiments conducted at strain rates of 580, 1550, and 2100 s ⁻¹ revealed rate‐dependent behavior. To analyze wave propagation and fracture evolution within the composite, a high‐fidelity mesoscale model was developed through a virtual manufacturing approach. This approach replicates the actual weaving process by representing each fiber as a chain of truss elements and transforming each curved bundle of fibers into a solid yarn generated by filling the space spanned by this fiber bundle with solid elements. Unrealistic yarn distortions and surface irregularities are addressed by applying some tensile stress on fibers and adjusting the reaction force between them, and then smoothing surfaces in Catia software. The remaining spaces are filled with matrix elements, arriving at the final geometric model. For the constitutive relations, yarns were modeled with transversely isotropic elasticity, matrix with isotropic elasticity–plasticity, and yarn–matrix interface with a cohesive model. Simulation results agree well with experimental stress–strain curves and damage patterns. Mesoscale simulations captured stress distributions and wave propagation within the components, revealing that yarns bear the majority of the load. Additionally, the simulations tracked fracture evolution, from the initiation of surface matrix cracking to yarn–matrix interface separation and eventual yarn fracture. These phenomena were driven by stress concentrations at the matrix surface and at the peaks and troughs of inner yarns, as revealed by the nonuniform stress distributions.