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<p>Accurate prediction of residual stresses in filament-wound composites is vital for their long-term performance and reliability. Many existing studies simplify these predictions by treating the fiber volume fraction (V<sub>f</sub>) as static, neglecting its evolution during manufacturing. In reality, however, multiple process parameters, such as consolidation pressure, continuously alter V<sub>f</sub> throughout the process, making such static approximations physically inconsistent with actual manufacturing behavior. To address this limitation, this study develops a comprehensive multiphysics simulation framework that captures the consolidation-driven evolution of V<sub>f</sub>, resin pressure, temperature, and degree of cure (DoC) in filament-wound composites. The framework integrates thermochemical, resin-flow, and mechanical fields via finite element subroutines. The effects of consolidation-driven V<sub>f</sub> evolution on residual stress development are investigated. Results indicate that processing conditions significantly influence V<sub>f</sub>, which affects the thermochemical response and, consequently, the resulting mechanical performance by reducing internal exothermic heat generation and peak curing temperatures. These reductions suppress the thermal and chemical shrinkage strains responsible for residual stress buildup. Consequently, the framework predicts significantly lower residual stresses than those obtained using static-V<sub>f</sub> approximations. These insights highlight the importance of incorporating consolidation-driven V<sub>f</sub> evolution within simulation frameworks for accurate residual stress prediction, offering a more physically realistic tool for process and structural optimization of filament-wound composites.</p>

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A Multiphysics Approach for Predicting Residual Stress Development in Filament Wound Composites Considering Fiber Volume Fraction Evolution

  • 期刊论文

  • 发表日期：

    2026年1月23日

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  • Zain Ul Abideen,
  • Qizhong Huang,
  • Hao Zhang,
  • Yang Yang,
  • Yongjian Zheng,
  • Mengyuan Xu,
  • Zhe Sun,
  • Shiyong Sun

摘要

Accurate prediction of residual stresses in filament-wound composites is vital for their long-term performance and reliability. Many existing studies simplify these predictions by treating the fiber volume fraction (Vf) as static, neglecting its evolution during manufacturing. In reality, however, multiple process parameters, such as consolidation pressure, continuously alter Vf throughout the process, making such static approximations physically inconsistent with actual manufacturing behavior. To address this limitation, this study develops a comprehensive multiphysics simulation framework that captures the consolidation-driven evolution of Vf, resin pressure, temperature, and degree of cure (DoC) in filament-wound composites. The framework integrates thermochemical, resin-flow, and mechanical fields via finite element subroutines. The effects of consolidation-driven Vf evolution on residual stress development are investigated. Results indicate that processing conditions significantly influence Vf, which affects the thermochemical response and, consequently, the resulting mechanical performance by reducing internal exothermic heat generation and peak curing temperatures. These reductions suppress the thermal and chemical shrinkage strains responsible for residual stress buildup. Consequently, the framework predicts significantly lower residual stresses than those obtained using static-Vf approximations. These insights highlight the importance of incorporating consolidation-driven Vf evolution within simulation frameworks for accurate residual stress prediction, offering a more physically realistic tool for process and structural optimization of filament-wound composites.