Stochastic virtual testing laboratory for unidirectional composite coupons: from conventional to dispersed-ply laminates

Abstract Failure loads and modes of standard test coupons of general unidirectional laminates are predicted by a reliable virtual testing toolset based on the finite element method. This computational mechanics framework combines a cohesive-frictional constitutive formulation coupled with the kinematics of penalty-based contact surfaces to simulate interlaminar damage, and a sophisticated three-dimensional continuum damage model to predict intraply damage. This virtual testing laboratory was previously validated for conventional laminates and can be applied to composite materials screening, design, and certification. In the present work, the computational framework is enhanced with features to increase realism of the virtual tests and to allow generalization to a larger range of configurations. A relevant new feature is stochastic simulation that allows replicating realistic test campaigns. The demonstration of the enhanced stochastic virtual testing laboratory is performed on dispersed-ply laminates that, by not being constrained to conventional 0°, 90°, and ±45° ply arrangements, allow widening the design space of composites.