Abstract: The optimal control of needle punching process parameters is very important to improve the mechanical properties of carbon/carbon compo-site. The development of “virtual reality test” method based on simulation technology can quickly and concurrently optimize the optimal combination of needle punching process parameters. In this work, the unit cell model of needle-punched C/C composites (NP C/C) with different needling densities (25 pin/cm2, 36 pin/cm2, 64 pin/cm2 and 100 pin/cm2) is established, and the maximum stress criterion and Hashin failure criterion are applied to the failure analysis of fiber web layer and weft-free layer, respectively, based on the periodic boundary condition. The mechanism of the influence of the needling density on the damage failure mode and mechanical behavior of NP C/C is analyzed. It is found that with the increase of loading, the cracks first appear at the circumferential boundary of the needle-punched fiber bundle in both the fiber web layer and the weft-free layer. Moreover, the cracks appear a “Cross” type which is nearly ±45° with the direction of loading. For C/C composite with higher needled density, the proportion of damage area caused byneedle-punched fiber bundles is higher, making it more prone to transverse cracks perpendicular to the loading direction, thereby weakening the material’s load-bearing capacity. Compared to 25 pin/cm2, the fracture strength of NP C/C with needle density of 36 pin/cm2, 64 pin/cm2, and 100 pin/cm2 decreases by 3%, 5%, and 19%, respectively. In addition, the results of secant stiffness degradation indicate that the mechanical behavior of NP C/C exhibits non-linearity before failure. This is mainly caused by progressive cracking damage during the tensile process. The model established in this paper can be used to guide the optimal design of the preform of NP C/C.
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2025, Vol. 39 
