A new alternative calculation procedure is developed to quantify the effect of yarn distortion characteristics on the mechanical properties of three-dimensional (3D) braided carbon/resin composites. Firstly, the multi-type yarn distortion characteristics factors including path, cross-section shape and cross-section torsion effects are described based on the stochastic theory. Then, the multiphase finite element method is employed to overcome the complex discretization in traditional numerical analysis, and the parametric studies including multi-type yarn distortion and different braided geometrical parameters on the resulting mechanical properties are performed. It is shown that the proposed procedure can simultaneously capture the yarn path and cross-section distortion characteristics caused by the mutual squeeze of component materials, which is difficult to characterize by experimental methods. In addition, it is found that even small distortions of yarn may significantly affect the mechanical properties for 3D braided composites, and the 3D braided composites with different braiding geometric parameters will show different sensitivity to the distortion characteristics factors of yarn. The procedure, which could be implemented into commercial finite element codes, is an efficient tool for the design and structural optimization analysis of a heterogeneous material with anisotropic properties or complex geometries.
Keywords: 3D braiding; carbon/resin composites; finite element analysis; mechanical properties; micro-distortion.