Automated image-based geometric modelling of thick laminates with three-dimensional ply wrinkles

ly wrinkles are commonly induced during thermal-mechanical manufacturing process of laminated composite structures or components. Fibre misalignment due to ply wrinkles compromises the structural integrity of a composite structure. The damage criticality can be assessed numerically based on non-destructive testing (NDT) results. Geometrical modelling is usually required and it is time-consuming if complex wrinkles have to be incorporated into the finite element model. This study presents an automated image-based three-dimensional geometric reconstruction method for thick laminates with complex ply wrinkles. The geometry of a thick laminate is reconstructed based on the limited inspection images from the sides of laminates. The two-dimensional geometrical reconstruction of the detected wrinkled plies is done using a multiple Gaussian functions model or linear interpolation, while the intermediate plies are defined by distance-based interpolation. Based on the reconstructed two-dimensional geometries, the three-dimensional ply wrinkles are modeled via an inverse distance weighting interpolation method. To verify the proposed method, a thick glass fibre laminate with artificially induced wrinkles is manufactured and the cross-sectional geometries of the reconstructed model are compared well with and the realistic inspection data. Progressive failure analysis of a two-dimensional and a three-dimensional reconstructed model are compared in terms of damage progression and load versus nominal strain response to highlight the relevance of modelling three-dimensional wrinkles to obtain more accurate and efficient damage criticality assessments.