An Enhanced Progressive Damage Model for Laminated Fiber-Reinforced Composites Using the 3D Hashin Failure Criterion: A Multi-Level Analysis and Validation

This paper presents a progressive damage model (PDM) based on the 3D Hashin failure criterion within the ABAQUS/Explicit^TM 2021 framework via a VUMAT subroutine, enhancing the characterization of the mechanical performance and damage evolution in the elastic and softening stages of composite materials via the accurate calculation of damage variables and accommodation of non-monotonic loading conditions. In the subsequent multi-level verification, it is found that the model accurately simulates the primary failure modes at the element level and diminishes the influence of element size, ensuring a reliable behavior representation under non-monotonic loading. At the laminate level, it also accurately forecasts the elastic behavior and damage evolution in open-hole lamina and laminates, demonstrating the final crack band at ultimate failure. This paper also emphasizes the importance of correct characteristic length selection and how to minimize mesh size impact by selecting appropriate values. Compared to ABAQUS's built-in 2D model, the 3D VUMAT subroutine shows superior accuracy and effectiveness, proving its value in characterizing the mechanical behavior and damage mechanisms of fiber-reinforced polymer (FRP) materials. The enhanced 3D PDM accurately characterizes the softening processes in composite materials under simple or complex stress states during monotonic or non-monotonic loading, effectively minimizes the mesh dependency, and reasonably captures failure crack bands, making it suitable for future simulations and resolutions of numerical issues in composite material models under complex, three-dimensional stress states.