Structural Optimization for Impact Performance of 3D Angle‐Interlock Woven Composites Using Gray Relational Analysis: Integrating Experiment With Numerical Simulation

ABSTRACT Three‐dimensional angle‐interlock woven composites (3DAWC) have been widely applied in automotive and aerospace exterior components due to their superior impact resistance. These composites are susceptible to barely visible impact damage (BVID) under low‐velocity impact (LVI), which demands further investigation into their resulting mechanical properties. This study investigates the mechanical performance of 3DAWC under LVI through a combined experimental and numerical simulation approach. A homogenization‐based finite element model was established based on metallographic microscopy for simulating the LVI response and interrogating the underlying damage mechanisms. The modeling method was validated by comparing the simulated mechanical response curves and damage patterns with experimental results. A combined approach of gray relational analysis and parameter analysis was applied to six structural parameters, identifying the key factors and optimal design for impact performance, which provides a guideline for engineering high‐impact‐resistant 3D woven composites.