Composite materials show different mechanical properties in different directions which leads to complications in the prediction of their behavior. In addition to being inhomogeneous, behavior of composite materials is highly dependent on the curing process and many studies have tried to address these issues. Residual stress can induce high errors in prediction of composite material properties and leads to a difference between theoretical and experimental results. It has been observed that the humidity of environment and the chemical properties of composite materials are also important. Fewer studies have addressed thick layer composites and no damage theory has been developed for these materials. In this paper residual stress in thick layer composites have been studied. Using numerical analysis, the curing process has been modeled and mechanical properties of a thick layer composite are obtained and the induced residual stress in these composites has been assessed. Unlike thin layer composites, the stress in each layer is not specific and a tensile and compressive stress field can exist simultaneously in thick layer composites.

The interphase is a region between fibers and a matrix, which has different properties from the matrix and the fibers, but is dependent on them. Considering the interphase region has a significant effect on the accuracy of obtained residual stresses. So far, in order to obtain the micromechanical residual stresses, the interphase properties are considered as an average. In this paper, the properties of the interphase are assumed variable by using a suitable UMAT code in the ABAQUS software. The equations of previous studies that have acquired interphase properties to be variable are used to write the UMAT code. A representative volume element (RVE) in polymer composites is modeled in three phases in the ABAQUS software and the interphase properties are considered as FGM by using the UMAT code. Temperature variation during curing to environment temperature is the only loading factor in the RVE. The matrix, fiber and interphase stresses are obtained in the ABAQUS software. The achieved stresses were compared with the results of previous studies that considered interphase properties as average. Finite element and energy methods were used in previous papers but in the present study just the finite element method with variable interphase properties was use. In addition, residual stress diagrams with the variable interphase properties are plotted to study the effect of the thermal expansion coefficient. The results of this study are similar to those in previous ones, and the curves are improved.