Research on Multi‐Scale Failure Evolution Mechanism of Rubber/Cord Composite Structures in Aircraft Tires Under Abnormal Conditions

ABSTRACT Rubber/cord composites, widely applied in aircraft tires and air springs, are prone to accumulating undetectable internal damage under abnormal loading conditions, often leading to catastrophic structural failures. Moreover, their damage processes and influencing factors are overly complex, making targeted failure control extremely difficult. This paper, combining experimental and theoretical methods, revealed their damage evolution mechanism: firstly, tensile loads would cause residual strains in cord strands, forming “Acquired Defects” as damage initiation; subsequently, damage would propagate along the rubber/cord interface, accelerated by axial compression and shear strain of cord layers; finally, uneven cord and weft arrangement would induce large‐scale damage propagation. Based on the mechanism, the regulation strategy could be raised: improve cord twisting or fiber materials to reduce residual strains to delay the appearance of Acquired Defects; reduce layer compression and shear strains by adjusting the structures; control cord/weft arrangement. This study provided critical insights and actionable guidelines for such composites.