Influence of the glass non-crimp fabric intrinsic undulation on the stiffness of the composite ply: A micromechanical approach

Load carrying components of modern wind turbine blades are manufactured from composites, consisting of non-crimp fabrics infused with polymer resins. The effective stiffness of the resulting laminate is a combination of the properties of its building blocks i.e. fibers, and matrix as well as from the fabric texture imperfections e.g. fiber undulations. Moreover, ply inherent boundary conditions, e.g. the restriction of the Poisson deformation of the matrix imposed from the adjacent fibers, are determining the in-situ orthotropic performance. Towards modelling the in-plane stiffness of a unidirectional (UD) infused non-crimp fabric, a two-step modular procedure is proposed, accounting for the aforementioned parameters, based only on experimental data and analytical formulations. Initially, a micromechanical model is predicting the stiffness of the ideal UD ply i.e. disregarding fiber undulations. Subsequently, a plate model is generated based on the classical lamination theory, approximating the UD laminate as a multiaxial configuration of ideal UD sub-plies. Each sub-ply thickness and orientation is based on the fiber angle density distribution of dry fabrics and cured laminates. These are derived experimentally with an integrated optical camera system and Computer Tomography scans respectively. The theoretical laminate stiffness is correlating very well with standard and thick UD laminate quasi-static tests.