Monte Carlo Micro-Stress Field Simulations in Flax/E-Glass Composite Laminae with Non-Circular Flax Fibres

This study explores the mechanical behaviour of intra-laminar hybrid flax/E-glass composites, focusing on the role of micro-scale irregularities in flax fibres. By employing computational micromechanics and Monte Carlo simulations, it analyses the influence of flax fibre geometry and elastic properties on the performance of hybrid and non-hybrid composites. A Non-Circular Fibre Distribution (NCFD) algorithm is introduced to generate microstructures with randomly distributed non-circular flax and circular E-glass fibres, which are then modelled using a 3D <i>representative volume element</i> (RVE) model developed in Python 2.7 and implemented with <i>Abaqus/Standard</i>. The RVE dimensions were specified as ten times the mean characteristic length of flax fibres (580 μm) for the width and length, while the thickness was defined as one-tenth the radius of the E-glass fibre. Results show that Monte Carlo simulations accurately estimate the effect of fibre variabilities on homogenised elastic constants when compared to measured values and Halpin-Tsai predictions, and they effectively evaluate the fibre/matrix interfacial stresses and von Mises matrix stresses. While these variabilities minimally affect the homogenised properties, they increase the presence of highly stressed regions, especially at the interface and matrix of flax/epoxy composites. Additionally, intra-laminar hybridisation further increases local stress in these critical areas. These findings improve our understanding of the relationship between the natural fibre shape and mechanical performance in flax/E-glass composites, providing valuable insights for designing and optimising advanced composite materials to avoid or delay damage, such as matrix cracking and splitting, under higher applied loads.