Abstract:
To address the separation between curing-process analysis and subsequent mechanical-performance prediction for thin-walled thermosetting carbon-fiber composite components, which makes it difficult to fully account for the effects of curing history on structural load-bearing and damage behavior, a sequentially coupled numerical model linking the manufacturing process and mechanical performance was developed for T700 carbon-fiber/epoxy flat laminates and V-shaped thin-walled components. The principal material parameters required for curing and progressive-damage analyses were obtained through differential scanning calorimetry, thermal-expansion, and intra- and interlaminar mechanical tests. Flat and V-shaped specimens with 0° and (0°/90°)
5s symmetric layups were manufactured. Cure-induced spring-in measurements, three-point bending tests of flat specimens, and three-point, four-point, and cantilever-supported bending tests of V-shaped specimens were conducted. The model first calculated the temperature field, degree-of-cure field, chemical shrinkage, cure-induced deformation, and nonuniform residual-stress field during curing. The cure-deformed finite element mesh and residual-stress field were then transferred unidirectionally to the subsequent bending analysis as the initial geometric configuration and initial stress state, respectively. On this basis, the 3D Hashin damage-initiation criterion, a fracture-energy-based intralaminar damage-evolution model, and an interlaminar cohesive damage model were integrated to establish a curing-history-driven framework for coupled intralaminar and interlaminar progressive-damage analysis. The measured mean spring-in angles of the 0° and (0°/90°)
5s V-shaped components were 0.638° and 1.961°, respectively, with corresponding numerical prediction errors of 10.14% and 8.79%. In the three-point bending analysis of the flat specimens, incorporating the curing residual stresses reduced the maximum relative error of the evaluated mechanical-performance metrics by 10.93 percentage points compared with the model excluding residual stresses. For the three bending configurations of the V-shaped components, the maximum relative error between the numerical and experimental results was 15.7%, and the model satisfactorily predicted the locations of damage initiation, the regions of delamination propagation, and the macroscopic failure modes. Scanning electron microscopy (SEM) revealed pronounced resin tearing and crack branching in the cross-ply specimens, resulting in relatively tortuous delamination paths. In contrast, the fracture surfaces of the 0° specimens were comparatively smooth, and cracks propagated preferentially along interlaminar resin-rich regions or fiber–matrix interfaces. These results demonstrate that the cure-deformed configuration and residual-stress state jointly affect load transfer and damage evolution in thin-walled composite components. The proposed sequentially coupled model provides a numerical basis for the integrated analysis of manufacturing accuracy and structural performance.