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© 2017, The Author(s) 2017. Resin transfer moulding is one of several processes available for manufacturing fibre-reinforced composites from dry fibre reinforcement. Recently, dry reinforcements made with Automated Dry Fibre Placement have been introduced into the aerospace industry. Typically, the permeability of the reinforcement is assumed to be constant throughout the dry preform geometry, whereas in reality, it possesses inevitable uncertainty due to variability in geometry. This uncertainty propagates to the uncertainty of the mould filling and the fill time, one of the important variables in resin injection. It makes characterisation of the permeability and its variability an important task for design of the resin transfer moulding process. In this study, variability of the geometry of a reinforcement manufactured using Automated Dry Fibre Placement is studied. Permeability of the manufactured preforms is measured experimentally and compared to stochastic simulations based on an analytical model and a stochastic geometry model. The simulations showed that difference between the actual geometry and the designed geometry can result in 50% reduction of the permeability. The stochastic geometry model predicts results within 20% of the experimental values.

The study focuses on unit cell FE modelling to predict coefficients of thermal expansion (CTEs) for sheared fabric laminates. Shear, as a dominant deformation mode in textile composites forming, introduces high degrees of anisotropy in both elasticity and thermal expansion. The unit cell predictions are based on realistic fibre architecture and measured material properties of constituent fibre and resin. Under the multi-scale framework, the unit cell predictions are part of the essential input data for locally varied material definitions. These definitions are used to model structural components to predict shape distortion. The FE model gives predictions close to the experimental data, when the boundary conditions are correlated to the coupon size. Nesting is an influential factor for CTEs. For true material representation, in-plane periodicity and nesting have been considered.

Experimental and numerical analysis of a woven composite were performed in order to assess the effect of yarn path and layer shift variability on properties of the composite. Analysis of the geometry of a 12K carbon fibre 2×2 twill weave at the meso- and macro-scales showed the prevalence of the yarn path variations at the macro-scale over the meso-scale variations. Numerical analysis of yarn path variability showed that it is responsible for a Young’s modulus reduction of 0.5% and CoV of 1% which makes this type of variability in the selected reinforcement almost insignificant for an elastic analysis. Finite element analysis of damage propagation in laminates with layer shift showed good agreement with the experiments. Both numerical analysis and experiments showed that layer shift has a strong effect on the shape of the stress-strain curve. In particular, laminates with no layer shift tend to exhibit a kink in the stress-strain curve which was attributed solely to the layer configuration.