In this work, we extend a recent surrogate modeling approach, the Physically Recurrent Neural Network (PRNN), to include the effect of debonding at the fiber–matrix interface of composite materials. The core idea of the PRNN is to implement the exact material models from the micromodel into one of the layers of the network to capture path-dependent behavior implicitly. For the case of debonding, additional material points with a cohesive zone model are integrated within the network, along with the bulk points associated to the fibers and/or matrix. The limitations of the existing architecture are discussed and taken into account for the development of novel architectures that better represent the stress homogenization procedure. In the proposed layout, the history variables of cohesive points act as extra latent features that help determine the local strains of bulk points. Different architectures are evaluated starting with small training datasets. To maximize the predictive accuracy and extrapolation capabilities of the network, various configurations of bulk and cohesive points are explored, along with different training dataset types and sizes.

This work represents the first step towards the application of machine learning techniques in the prediction of statistical design allowables of composite laminates. Building on data generated analytically, four machine algorithms (XGBoost, Random Forests, Gaussian Processes and Artificial Neural Networks) are used to predict the notched strength of composite laminates and their statistical distribution, associated to the uncertainty related to the material properties and geometrical features. This work focuses not only on the so-called Legacy Quad Laminates (0°/90°/±45°), typically used in the design of composite aerostructures, but also on the newer concept of double-double (or double-angle ply) laminates. Very good representations of the design space, translating in low generalization relative errors of around ±10%, and very accurate representations of the distributions of notched strengths around single design points and corresponding B-basis allowables are obtained. All machine learning algorithms, with the exception of the Random Forests, show very good performances, with Gaussian Processes outperforming the others for very small number of data points while Artificial Neural Networks have better performance for larger training sets. This work serves as basis for the prediction of first-ply failure, ultimate strength and failure mode of composite specimens based on non-linear finite element simulations, providing further reduction of the computational time required to virtually obtain the design allowables for composite laminates.