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

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

Open Access
|Jun 2026

Figures & Tables

Fig. 1.

Composite Fan Cases for high-bypass turbofan jet engines (GEnx [9], GE9X [10], CFM LEAP [11], RR Trent 1000 [12]).

Fig. 2.

Levels of damage idealization (adopted from [21]).

Fig. 3.

Experimental photographs and finite element predictions of failed specimens with failure locations highlighted (adopted from [33]).

Fig. 4.

Comparison of experimental and numerical load-displacement analysis, showing delamination pattern (adopted from [34]).

Fig. 5.

omparison of experimental X-ray radiography and numerical damage progression (adopted from [36]).

Fig. 6.

Comparison of experimental and numerical results for progressive damage in a bolted joint (adopted from [37]).

Fig. 7.

Failure modes of composite bolted joints: (a–d) geometrical variables and schematic failure modes, (e) experimental bearing damage at varying e/D ratios, and (f) numerical strain fields under tension and compression (adopted from [38]).

Qualitative comparison of failure criteria_

CriterionStrengthsLimitationsTypical Use Cases
Hashin (1980)Simple, few parameters; distinguishes basic modes; widely available in FEA codesNo crack angle prediction; can mispredict matrix-heavy failures (non-conservative in some cases)Preliminary design, fiber-dominated failures (e.g. tension of UD plies)
Puck (1998, 2002)Physical basis for matrix failure; predicts fracture angle; better for shear/compression casesMore complex; requires extra parameters (e.g. interface friction); not standard in all codesDetailed analysis of matrix-sensitive problems (open-hole compression, shear-out, etc.)
LaRC04/05 (2004)Accounts for fiber kinking and matrix splitting with advanced criteria; very good correlation in many studiesImplementation not widely built-in (user subroutine often needed); moderate complexityHigh-fidelity analysis where both fiber and matrix failures interact (e.g., impact, CAI, complex combined loads)

Correlation of FE models with tensile tests on bolted composite joints (single-lap joints under tension, comparing experimental failure load to simulation)_

ReferenceJoint ConfigurationExp vs. FE Failure Load CorrelationNotable Modeling Features
Yoon et al. (2020) [38]Single-bolt, varying edge distance (e/D) in CFRP laminatesFE predicted failure load within ~10% of test (transitions from bearing to net-tension captured)3D continuum model; included bolt clamp-up and friction
Cameron et al. (2021) [59]Thick-ply vs. thin-ply laminate, open-hole bearing testPredicted strength within ~5–10% of experiments (thin-ply showed more gradual failure)Continuum damage model; calibrated toughness for thin plies
Montagne et al. (2016) [55]Multi-bolt single-lap joint (3 bolts in line)Strong agreement in stiffness and failure load (difference only a few percent; mode sequence matched)Cohesive interface elements to capture delamination in joint, 3D solid model

Selected results for open-hole tension & bearing failure correlations_

ReferenceComposite System and TestExp vs. FE CorrelationNotes (Failure Mode)
Xiao & Ishikawa (2005) [36]Open-hole tension (OHT) in quasiisotropic CFRP couponsFE predicted first-ply failure location accurately; ultimate load within ~5% of test (bearing mode)3D Hashin criteria; element removal after failure
Dogan et al. (2024) [60]Pin-loaded bearing-bypass test (tension + bearing)Puck criterion simulation captured crack path and strength better than Hashin (error <10%)Puck’s angled fracture plane matched inclined matrix cracks
Cameron et al. (2022) [59]Open-hole bearing, thick vs. thin ply laminatesFE vs test failure load difference ~5% (thin-ply) to 10% (thick-ply)Continuum damage model; thin-ply laminate showed more gradual damage spread

Correlation in composite repair strength predictions

ReferenceDescription of RepairFE vs Test Strength OutcomeNotable Findings
Baker & Bitton [24]Scarf patch repair on CFRP panel (simulated)Predicted failure location in FE matched test – failure in parent laminate (not at adhesive) for optimal shallow scarfScarf 1:50 restored ≥ 95% strength; steep scarf had interface failure
Duong et al. [26]Resin injection repair for delamination (tested)FE matched exp. failure load within ~10%Repair holes caused negligible stress; restored panel carried >90% of original load

j_tar-2026-0010_tab_101

σ11is the normal stress along the fiber direction,
σ22is the normal stress acting in the direction transverse to the fibers,
τ12 and τ13are the shear stresses in planes containing the fiber axis,
XTis the tensile strength of the composite along the fibers,
XCis the compressive strength of the composite along fibers,
YTis the tensile strength of the composite in direction transverse to the fibers,
YCis the compressive strength of the composite in direction transverse to the fibers,
Sis the composite shear strength.

Correlation of simulation and experiments in Compression-After-Impact (CAI) tests_

ReferenceImpact Energy & DamageResidual Compression Strength: FE vs TestRemarks on Model Accuracy
Lu et al. (2020) [61]Quasi-isotropic carbon/PEKK panel, 30 J impact (BVID)FE predicted CAI strength within 5% of testIncluded high interlaminar toughness of thermoplastic (better than epoxy)
Bull et al. (2013) [62]Carbon/epoxy panel with known impact damage (CT scanned)FE within ~5% of test residual strengthImage-based model imported actual damage; matched failure pattern accurately
Guo et al. (2021) [65]Carbon/epoxy, various impacts (parametric study)Model adjustable to <10% error in strengthShowed sensitivity to input data; proper calibration needed for each layup
Language: English
Page range: 86 - 118
Submitted on: Sep 1, 2025
Accepted on: Apr 21, 2026
Published on: Jun 17, 2026
In partnership with: Paradigm Publishing Services

© 2026 Robert Jan Młot, published by ŁUKASIEWICZ RESEARCH NETWORK – INSTITUTE OF AVIATION
This work is licensed under the Creative Commons Attribution-NonCommercial-NoDerivatives 4.0 License.