Numerical Simulation of Composite Structural Failure: A Review of Methods and Correlation with Destructive Tests

Advanced composite structures are widely used in aerospace and related industries, yet manufacturing defects and in-service damage can significantly reduce their structural integrity, necessitating costly destructive testing. This article reviews numerical methods for simulating composite structural failure, drawing on literature from 2015 to 2024, and assesses their correlation with destructive test results. Progressive damage models, cohesive zone modeling, and finite element implementation strategies are discussed across a range of scenarios including bolted joint failures, open-hole tension, compression-after-impact, and bonded repairs. Well-calibrated models are shown to predict failure loads within 5–15% of experimental values and to reproduce failure modes including fiber fracture, matrix cracking, and delamination. The choice of failure criterion – Hashin, Puck, or LaRC – is found to significantly affect accuracy in matrix-dominated cases. The review concludes that validated numerical simulation offers a credible complement to physical testing in composite certification, with remaining challenges in multiscale modeling, environmental effects, and regulatory acceptance identified as priorities for future research.