Virtual Manufacturing of Composite Panels with Embedded Sensors Using Layer-Wise Multi-Field Models

The failure of composite materials remains a critical challenge in engineering applications, necessitating innovative approaches to enhance their reliability and lifespan. Health monitoring systems have emerged as a promising solution for predicting the residual life of these materials. Embedded sensors enhance the sensitivity and accuracy of such monitoring systems but introduce significant complexities in the design and manufacturing of composite panels. These sensors may act as potential defect sources, compromising structural integrity. Additionally, manufacturing processes often induce residual stresses and deformations due to the differing material properties, further complicating the overall system behavior. This study addresses these challenges through an advanced simulation approach based on the Carrera Unified Formulation (CUF), providing a virtual manufacturing environment to assess the impact of embedded sensors on composite materials. The proposed methodology employs layer-wise modeling, enabling a detailed mesoscale description of the composite structure. This approach accurately captures interlaminar stress distributions and residual deformations while offering a high-fidelity representation of the interface between the sensor and the structure. Moreover, a multi-field description of the sensors allows for simulations that incorporate electromechanical and thermal behaviors, offering insights into their role during the curing process and exploring the feasibility of monitoring the manufacturing process using the embedded devices. The results demonstrate the significant influence of embedded sensors on residual stresses, underscoring the need for advanced modeling techniques to address the complex stress states generated. This study validates the effectiveness of CUF-based models in capturing the complexities of composite-sensor interactions and highlights their potential for optimizing manufacturing processes. Such advanced simulations are crucial for the reliable integration of sensors, ensuring efficient production and the long-term structural performance of composite materials.