Development of a Computational Design Framework for Multi-Scale Modelling of Woven Technical Textile Reinforcements for Composite Aerospace Structures

The design and prediction of the mechanical behaviour of woven textile-reinforced composites for structural aerospace applications requires multi-scale modelling capabilities that bridge the yarn-level fibre architecture with macroscale composite performance. This research develops a comprehensive computational framework for multi-scale modelling of woven textile reinforcements, with application to carbon fibre woven composites relevant to the emerging Nigerian aerospace component manufacturing sector. The framework integrates micro-scale fibre/matrix unit cell models, meso-scale yarn-level representative volume elements incorporating realistic woven geometry from micro-computed tomography imaging, and macro-scale laminate finite element models. Uncertainty quantification by Monte Carlo sampling addresses the inherent variability in woven fabric geometric parameters. Progressive damage models incorporating intraply matrix cracking, fibre fracture, and interlayer delamination mechanisms were implemented within the multi-scale hierarchy. Experimental validation employed digital image correlation full-field strain mapping on quasi-static tensile and fatigue specimens of carbon/epoxy plain weave composites. The framework was applied to investigate the effect of weave architecture, including plain, twill, and satin, on composite mechanical response and damage initiation under combined tension-shear loading, relevant to wing skin panel loading conditions. Results demonstrate that macro-scale tensile modulus predictions agreed within 6 percent of experimental values without any empirical fitting. Damage initiation strain predictions showed 9 percent mean error. Satin weave architectures demonstrated superior resistance to in-plane shear damage initiation compared to plain weave at equivalent fibre volume fraction. The computational framework provides Nigerian composite engineering researchers and manufacturers with a validated predictive tool for woven composite design, reducing dependence on extensive experimental test programmes. Keywords: multi-scale modelling, woven composite, textile reinforcement, computational framework, progressive damage