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

Abstract 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.