Simulation of Damage Sensing in Smart Self-Sensing Composites for Digital Design Integration

Smart composite materials with integrated sensing layers are gaining attention for their potential to improve structural health monitoring and damage detection in high-performance applications. This study experimentally evaluates validated advanced simulation techniques to investigate impact-induced damage in such composites, with a particular focus on barely visible impact damage (BVID). A refined finite element model is developed using user-defined cohesive materials to capture both matrix cracking and delamination, which are critical to understanding damage mechanisms associated with BVID. The model is applied to hybrid laminates incorporating surface-integrated sensing layers composed of ultra-high modulus carbon and S-glass fibres. These layers are designed to show visible signs of damage that can be correlated with internal failure mechanisms. The simulation results are compared against experimental data, including C-scan imaging and surface inspections, to assess accuracy in predicting damage initiation, growth, and patterns. Particular attention is given to the effects of through-thickness compression and the interaction between different failure modes. This work offers practical insights for reducing reliance on costly testing during the early stages of material and structural design for smart composites.