Ply wrinkles are commonly induced during thermal–mechanical manufacturing process of laminated composite structures or components. Fibre misalignment due to ply wrinkles compromises the structural integrity of a composite structure. The damage criticality can be assessed numerically based on non-destructive testing results. Geometric modelling is usually required and it is time-consuming if complex wrinkles have to be incorporated into the finite element model. This study presents an automated image-based three-dimensional geometric reconstruction method for thick laminates with complex ply wrinkles. The geometry of a thick laminate is reconstructed based on the limited inspection images from the sides of laminates. The two-dimensional geometric reconstruction of the detected wrinkled plies is done using a multiple Gaussian functions model or linear interpolation, while the intermediate plies are defined by distance-based interpolation. Based on the reconstructed two-dimensional geometries, the three-dimensional ply wrinkles are modelled via an inverse distance weighting interpolation method. To verify the proposed method, a thick glass fibre laminate with artificially induced wrinkles is manufactured and the cross-sectional geometries of the reconstructed model are compared well with and the realistic inspection data. Progressive failure analysis of a two-dimensional and a three-dimensional reconstructed model are compared in terms of damage progression and load versus nominal strain response to highlight the relevance of modelling three-dimensional wrinkles to obtain more accurate and efficient damage criticality assessments.

在层压复合结构或组件的热机械制造过程中，通常会引起层褶皱。由于铺层褶皱导致的纤维错位会损害复合结构的结构完整性。可以根据无损检测结果对损伤临界程度进行数值评估。通常需要几何建模，如果必须将复杂的皱纹纳入有限元模型，则非常耗时。本研究提出了一种基于图像的自动三维几何重建方法，用于具有复杂层褶皱的厚层压板。厚层压板的几何形状是根据来自层压板侧面的有限检查图像重建的。检测到的褶皱层的二维几何重建是使用多高斯函数模型或线性插值完成的，而中间层由基于距离的插值定义。基于重建的二维几何结构，通过反距离加权插值法对三维层褶皱进行建模。为了验证所提出的方法，制造了一个带有人工褶皱的厚玻璃纤维层压板，并将重建模型的横截面几何形状与实际检测数据进行了比较。