Simulation of Staggered Composites Under Tensile and Interlaminar Fracture Loading: Python Scripting, Numerical Assessment, and Architectural Effects

This study presents a parametric Python framework to automate two-dimensional finite element model generation of staggered brick-and-matrix composites in Abaqus/Standard. The suite includes four standalone scripts—for periodic and finite-gauge tensile models, double-cantilever beam (DCB), and three-point end-notched flexure (3ENF) specimens—with three complementary plug-ins that generate editable, native Abaqus/CAE databases. User-defined parameters govern key geometric variables (brick length, ply count, layer offset), material assignments, cohesive interfaces, pre-cracks, boundary conditions, and mesh discretization, facilitating systematic architectural evaluations. To ensure numerical robustness, an analysis of potential numerical artifacts, mesh sensitivity, and the validity of a representative volume element (RVE) under highly nonlinear conditions was conducted. Given the mesh sensitivity of progressive Hashin damage predictions, two spatial initiation-based post-processing criteria were evaluated as less mesh-sensitive failure-onset indicators. Experimental comparisons informed the choice of a working mesh for progressive simulations. Using this setup, the framework was used to investigate the mechanical effects of brick length and layer offset. Architectural comparisons showed that aligned matrix pockets produced the lowest tensile stiffness and load capacity, whereas half- and quarter-pitch offsets achieved the highest tensile stiffness and strength among non-aligned configurations.