A coupled thermo-chemo-mechanical reduced-order multiscale model for predicting process-induced distortions,residual stresses,and strength

We study residual stresses and part distortion induced by a manufacturing process of a polymer matrix composite and its effect on the component strength. Unlike most of the thermo-chemo-mechanical models in the literature where governing multiphysics equations are directly formulated on the macroscale, we present a multiscale-multiphysics approach. To address the enormous computational complexity involved, a reduced-order homogenization was originally developed for a single physics problem is employed. The proposed reduced-order two-scale thermo-chemo-mechanical model has been validated for predicting part distortion beam strength in three-point bending test. It is shown that while macroscopic stresses are relatively low, and therefore often ignored in practice, stresses at the scale of microconstituents are significant and may have an effect on the overall composite component strength.