Impact of layer orientation and interlayer inhomogeneity on the bending properties of plain weave <scp>CFRP</scp> laminates

Abstract Plain weave carbon fiber reinforced polymer (CFRP) laminates have garnered widespread attention in the aerospace and automotive industries due to their exceptional mechanical properties and lightweight structure. During the production of laminates, the thickness of each layer is often nonuniform. In traditional finite element analysis (FEA), the laminates are usually assumed to be uniformly layered, which can introduce some errors. Thus, there is room for improvement in prediction accuracy. This study explores the bending performance of plain weave CFRP laminates at different orientation angles of the layers, employing both experimental and FEA. In contrast to traditional methods, using images of weave structures captured by metallographic microscopy to create the representative volume element (RVE) model can improve the precision of FEA. Bending tests are conducted on specimens with orientation angles at 0° and 45°, while the bending modulus for orientation angles at 15° and 30° are predicted through FEA methods. This research enhances the accuracy of the mechanical performance analysis of plain weave CFRP laminates and also uncovers the relationship between the bending modulus changes and the orientation angles. It provides a theoretical foundation and guidance for optimizing the structural design and improving the mechanical properties of woven laminates. Highlights Investigated plain weave CFRP laminate mechanics via homogenization. Microscopy‐based RVE model improves FEM bending modulus prediction. Effects of orientation angles on plain weave CFRP laminate bending performance.