Meso-scale simulation of cross-ply UHMWPE composite laminates under general out-of-plane compressive loading

With an exceptional combination of low density and mechanical properties, cross-ply ultra-high molecular weight polyethylene (UHMWPE) composite laminates are increasingly exploited in civil engineering and armor protection systems, yet the design and analysis of such composite structures necessitate the development of efficient simulation tools that can optimally balance computational efficiency with predictive accuracy. Building upon our prior micro-scale FE model, a new meso‑scale approach is developed for simulating larger-sized cross-ply UHMWPE laminates. This innovative meso‑scale model accurately captures the fiber-scale deformation and failure mechanisms of composites while maintaining high computational efficiency. The validity of the proposed meso‑scale numerical methodology has been thoroughly validated by comparing it against extensive experimental data, including quasi-static compression, indentation, drop-weight impact, and ballistic impact tests, with remarkable agreement across all simulations. Compared to traditional homogenization models, the meso‑scale model significantly improves the resolution in predicting the mechanical response and deformation processes of composites. The new model also overcomes their shortcoming of overlooking internal composite structures and provides new insights into the anisotropic deformation mechanisms of fibers and resins under general out-of-plane loadings. This work represents a novel implementation of a meso‑scale numerical model specifically developed for the design and optimization of cross-ply UHMWPE composite laminates, offering significant advancements in the simulation and analysis of protective structures made of advanced composite materials.