A Microscale Analysis of Thermal Residual Stresses in Composites with Different Ply Orientations

Abstract

Composites, such as fiber-reinforced plastics, are produced using layering prepregs with varying ply orientations to achieve enhanced mechanical properties. However, this results in intricate residual stresses, which are influenced by the forming process and ply orientation. In this study, three representative microscopic models—featuring discrete fiber and resin—represent unidirectional, cross-ply, and angle-ply laminates. These models underwent simulations under three different cooling histories using the finite element method. The findings suggest that ply orientation does not significantly influence temperature distribution. However, it significantly impacts the von Mises stress in the fiber closest to the interface between two stacked laminae. This differs from the inter-laminar stresses determined with the macroscopic lamination model. Apart from the free edge, which exhibits a complex stress distribution, the von Mises stress within a unit cell displays a recurring pattern. The magnitude of the von Mises stress decreases as the ply orientation angle increases and shifts when a temperature gradient is present throughout the composite’s thickness. This study provides valuable insights into the mechanics of residual stresses at the microscopic level and highlights potential defect areas influenced by these stresses.