The main goal of this study was to investigate the effect of tow tension and related internal micro-structure on the damage behavior of 3D orthogonal woven composites under tensile loading. For representing the internal micro-structure of the composite with respect to varying tow cross-section and the unregulated undulated path which are introduced by Z-binder tension, a dynamical method at filament level which simulates an interlacing process was used to obtain the fabric architecture. Then, an element recognition algorithm was proposed to convert a representative unit cell of 3D woven fabric architectures into a finite element model with 8-node solid elements consisting of four kinds of sets in terms of warp, weft, Z-binder tows and resin matrix. In addition, filament trajectory was also extracted from fabric architecture to serve as a local material orientation. Comparative simulations under tensile loading were conducted on the FEA models generated by this work and texgen software, respectively. An experiment was also carried out to verify the simulation results. The stress–strain curve in the proposed model was found to be closer to the experiment data. The results show that the tensile modulus and strength reduce due to the diverged warp tow path which is induced by the interaction between the tows during the weaving process. Moreover, the irregularity and compressed weft tow cross-sections nearby the intercross point are more likely to generate the transverse damage which would result in the non-linear tensile behavior of the composite material.
