Abstract—A 3D woven composite, designed for automotive applications, is studied using Abaqus Finite Element (FE) software suite. Python scripts were developed to build FE models of the woven composite in Complete Abaqus Environment (CAE). They can read TexGen or WiseTex files and automatically generate consistent meshes of the fabric and the matrix. A user menu is provided to help define parameters for the FE models, such as type and size of the elements in fabric and matrix as well as the type of matrix-fabric interaction. Node-to-node constraints were imposed to guarantee periodicity of the deformed shapes at the boundaries of the representative volume element of the composite. Tensile loads in three axes and biaxial loads in x-y directions have been applied at different Fibre Volume Fractions (FVFs). A simple damage model was implemented via an Abaqus user material (UMAT) subroutine. Existing tools for homogenization were also used, including voxel mesh generation from TexGen as well as Abaqus Micromechanics plugin. Linear relations between homogenised elastic properties and the FVFs are given. The FE models of composite exhibited balanced behaviour with respect to warp and weft directions in terms of both stiffness and strength. Keywords—3D woven composite, meso-scale finite element modelling, homogenisation of elastic material properties, Abaqus Python scripting. I. INTRODUCTION UTOMOTIVE industry has benefitted from advantages of the composite materials. They offer reduction of cost and weight while improving performance in terms of stiffness and strength of the parts among other advantages . Woven composites are widely used in auto-sector, while 3D Woven Composites (3WCs) are poised to add a new dimension to the applicability of the composite materials. Composites with 3D woven reinforcements have the potential to yield higher FVF, better out of plane stiffness and strength as well as avoidance of (interlaminar) delamination [1]-[5]. Thus, research into understanding the mechanical behaviour of 3DWCs can be important for advancement of composite technology and broadening of their range of applications. Woven fabrics are used alongside braided, knitted and non-woven reinforcements . There are many definitions for a 3D fabric . One such definition is given by . An early review of applications for 3D A. R. Zamani is with the Institute for Innovation in Sustainable Engineering (IISE), University of Derby, UK (e-mail: a.zamani@derby.ac.uk). L. Sanguigno is a research fellow at the IISE, University of Derby, UK (e- mail: l.sanguigno@derby.ac.uk). A. R. Maligno is the Research Chair in Composite Materials at the IISE, University of Derby, UK (e-mail: a.maligno@derby.ac.uk). This work has been conducted as part of the TMAP project, which is funded by Innovate UK (part of UK Research and Innovation). is given by . Overall view of the numerical approaches for analysis of 3D composites can be found in , and also . 3D fabrics can be woven is vast variations. This makes the geometry of the composites challenging for mathematical or computational modelling. Here, a 3D layer-to-layer fabric is analysed by FE method using Abaqus FE solver in the context of CAE. The fabric weave, as illustrated in Fig. 1, has been designed by MWright & Sons ltd. for the purpose of automotive parts. It shows that two warp layers and three weft layers are woven together by two layers of binder yarns, which are interleaved between warp yarns with a ratio of one to one. There are four yarns in each warp and weft layer. In fact, two Representative Volume Element (RVE) of the composite are displayed in Fig. 1, along the warp axis, namely in terms of weft columns. Fig. 1 Geometric model of the weave design in TexGen (dimensions in mm) The woven fabric has been used to produce composite samples. FE analysis of these samples is presented in this article. In this study, three geometric models were built and analysed using Abaqus with five different Intra-Yarn Fibre Volume Fractions (IYFVFs). Three different methods are also applied for ensuring periodicity at the boundaries of the RVE. Definitions for volume fractions are given in Subsection II B, while details of the constituent materials of the composite are given in Section III. II. GEOMETRIC MODELLING Adjustment of the Geometric Model in TexGen A. TexGen [9], [10] and WiseTex are prominent among software for geometric modelling and visualisation of textiles, fabrics and composites. TexGen is a free and open source software and is used in this study, e.g. for rendering of the design model in Fig. 1. To evaluate the actual fabric structure, a piece of the composite was CT scanned. Fig. 2 shows a Finite Element Modelling of a 3D Woven Composite for Automotive Applications Ahmad R. Zamani, Luigi Sanguigno, Angelo R. Maligno A World Academy of Science, Engineering and Technology International Journal of Mechanical and Materials Engineering Vol:14, No:11, 2020 546 International Scholarly and Scientific Research & Innovation 14(11) 2020 ISNI:0000000091950263 Open Science Index, Mechanical and Materials Engineering Vol:14, No:11, 2020 publications.waset.org/10011601/pdf