Digital element approach based automated conformal mesh generation methodology for meso-scale modeling of realistic textile composites and progressive failure analysis under compressive load

A structured method to generate conformal finite element (FE) mesh for realistic 3D woven textile reinforced composite is proposed. It is based on a voxel structure mesh reconstruction framework and aims to provide accurate composite model at yarn level with material properties ready for use in commercial FE software. The textile representative volume element (RVE) is generated at filament level implementing the digital element method. Yarn structure is determined by filament bundle with variant cross-section shapes along its path. Yarn surface is then extracted using the Delaunay triangulation algorithm and a surface mesh is initiated. Then, the mesh domain is defined and constructed by voxel structure. Periodic boundary conditions, inter-yarn, and yarn-matrix interfaces are eliminated by re-mesh and mesh optimization. An element splitting rule is established to split the voxel unit into sub-elements to create smooth interface. A 3D orthogonal weave fabric reinforced composite is generated and simulated under compressive load. The composite structure and damage morphology are in good agreement with those of the experiment.