Manufacturing, Progressive Damage Modeling, and Multiobjective Optimization of 3D Angle‐Interlock Woven Composites Under Tensile Loading

This study investigates the manufacturing process, progressive damage behavior, and multiobjective structural optimization of 3D angle‐interlock woven composites (3DAWCs) fabricated via the resin transfer molding process. The 3DAWCs consist of T700‐12K carbon fiber preforms and an epoxy matrix system (LT‐5028A/B). A representative volume element model is constructed from metallographic measurements. An enhanced Linde‐based progressive damage model incorporating shear coupling was implemented through the user‐defined material subroutine to capture the damage evolution of complex woven architectures. The numerical model is validated against uniaxial tensile tests in both warp and weft directions. And this model is employed to investigate the effects of the viscosity regularization coefficient and porosity on the mechanical response. Furthermore, an orthogonal experimental design combined with Pareto effect analysis and response surface methodology is employed to evaluate the effects of yarn spacing, width, and height on the warp‐ and weft‐direction peak stress and Young's modulus. The results indicate that weft height is the dominant parameter affecting the tensile strength, whereas warp width has a significant influence on stiffness. The optimized configurations achieve a balance between strength and stiffness in different loading directions, demonstrating the potential of mesostructural design for improving the mechanical performance of 3DAWCs.