A 3D Modelling Approach for Fluid Progression during Process Simulation of Wet Compression Moulding – Motivation &amp; Approach

Poppe, Christian; Albrecht, Fabian; Krauß, Constantin; Kärger, Luise

doi:10.1016/j.promfg.2020.04.141

Cited by 11 publications

(9 citation statements)

References 12 publications

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“…during the compaction trial in case the fabric is impregnated, also investigated by Poppe et al [22]. The higher the viscosity the higher the necessary additional pressure.…”

Section: Reactive Polyurethane Foam System Developmentmentioning

confidence: 95%

“…The average pressure curves increase from dry fabric over 100 mPa•s to 500 mPa•s. This effect is due to the necessary additional pressure to enable the fluid flow (fluid pressure) during the compaction trial in case the fabric is impregnated, also investigated by Poppe et al [22]. The higher the viscosity the higher the necessary additional pressure.…”

Section: Compaction Analysis Of the Face Sheet Fabric Materialsmentioning

confidence: 98%

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Development of a Reactive Polyurethane Foam System for the Direct Sandwich Composite Molding (D-SCM) Process

et al. 2021

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Sandwich structures utilize the geometric stiffening effect by increasing the area moment of inertia. This reduces carbon fiber (CF) material within CF-reinforced plastic (CFRP) components, and thus, the CO2 footprint. A suitable material combination for lightweight design is the use of continuous fiber-reinforced face sheets with a light foam core. CFRP sandwich structures with foam core are manufactured by combining a prefabricated foam core with fiber-reinforced cover layers in a two-step press process. Besides the reduction of the used CFRP material, more efficient manufacturing processes are needed. The aim of this paper is to develop a novel polyurethane foam system to enable the direct sandwich composite molding (D‑SCM) process for the production of CFRP sandwich structures by utilizing the resulting foaming pressure during the reactive polyurethane (PUR) foam system expansion for the impregnation of the CF reinforced face sheets. The developed formulation enables D-SCM structures with 150–250 kg/m3 foam density and 44–47.5% fiber volume content, based on a preliminary evaluation.

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“…during the compaction trial in case the fabric is impregnated, also investigated by Poppe et al [22]. The higher the viscosity the higher the necessary additional pressure.…”

Section: Reactive Polyurethane Foam System Developmentmentioning

confidence: 95%

Section: Compaction Analysis Of the Face Sheet Fabric Materialsmentioning

confidence: 98%

Development of a Reactive Polyurethane Foam System for the Direct Sandwich Composite Molding (D-SCM) Process

et al. 2021

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“…To parametrizes transverse compaction behavior of the UD-NCF, dry compaction trials with a six ply stack are carried out using a punch-to-plate setup [6] as displayed in Figure 2 Pre-infiltrated compaction experiments are conducted in order to verify the introduced additional fluid response within the model. Experimental results show a strong increase in reaction force and a shift towards lower compaction states when fluid is present.…”

Section: P Par Arametrization and V Ametrization And Verification Erificationmentioning

confidence: 99%

“…Outline Outline. In this work, a formerly presented macroscopic modelling approach for three-dimensional fluid progression during draping [6,23] The extended three-dimensional process simulation approach for WCM utilizes a fully-coupled forming and fluid submodel implemented in ABAQUS/EXPLICIT to account for large deformations and simultaneous fluid progression. This is enabled via stacked built-in continuums shells and user elements representing the single plies in a finite element manner.…”

mentioning

confidence: 99%

Towards numerical prediction of flow-induced fiber displacements during wet compression molding (WCM)

Poppe¹,

Albrecht²,

Krauß³

et al. 2021

Esaform 2021

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Wet compression molding (WCM) provides large-scale production potential for continuous fiber-reinforced structural components due to simultaneous infiltration and draping during molding. Due to thickness-dominated infiltration of the laminate, comparatively low cavity pressures are sufficient – a considerable economic advantage. Experimental and numerical investigations prove strong mutual dependencies between the physical mechanisms, especially between resin flow (mold filling) and textile forming (draping), similar to other liquid molding techniques (LCM). Although these dependencies provide significant benefits such as improved contact, draping and infiltration capabilities, they may also lead to adverse effects such as flow-induced fiber displacement. To support WCM process and part development, process simulation requires a fully coupled approach including the capability to predict critical process effects. This work aims to demonstrate the suitability of a macroscopic, fully coupled, three-dimensional process simulation approach, to predict the process behavior during WCM, including flow-induced fiber displacements. The developed fluid model is superimposed to a suitable 3D forming model, which accounts for the deformation mechanisms including non-linear transverse compaction behavior. A strong Fluid-Structure-Interaction (FSI) enforced by Terzaghi’s law is applied to assess flow-induced fiber displacements during WCM within a porous UD-NCF stack in a homogenized manner. Accordingly, resulting local deformations are considered within the pressure field. All constitutive equations are formulated with respect to fiber deformation under finite strains. Results of a parametric study underline the relevance of contact conditions within the dry and infiltrated stack. The numerically predicted results are benchmarked and verified using both own and available experimental results from literature.

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“…State of the art forming simulation approaches mainly apply conventional two-dimensional shell approaches [5] to efficiently model the deformation of thin fibrous reinforcements, since they allow for high aspect ratios while still accurately describing the membrane and bending behaviour. However, those approaches cannot model out-of-plane compaction, which is an important forming mechanism to predict local fibre volume contents [6] and influences the permeability of the reinforcement during processes such as wet compressions moulding [7,8]. To predict these effects and the final thickness of the part, a three-dimensional FE-formulation is necessary.…”

Section: Intr Introduction Oductionmentioning

confidence: 99%

Potential and challenges of a solid-shell element for the macroscopic forming simulation of engineering textiles

Schäfer¹,

Dörr²,

Kärger³

2021

Esaform 2021

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Finite element (FE) forming simulation offers the possibility of a detailed analysis of the deformation behaviour of engineering textiles during forming processes, to predict possible manufacturing effects such as wrinkling or local changes in fibre volume content. The majority of macroscopic simulations are based on conventional two-dimensional shell elements with large aspect ratios to model the membrane and bending behaviour of thin fabrics efficiently. However, a three-dimensional element approach is necessary to account for stresses and strains in thickness direction accurately, which is required for processes with a significant influence of the fabric’s compaction behaviour, e.g. wet compression moulding. Conventional linear 3D-solid elements that would be commercially available for this purpose are rarely suitable for high aspect ratio forming simulations. They are often subjected to several locking phenomena under bending deformation, which leads to a strong dependence of the element formulation on the forming behaviour [1]. Therefore, in the present work a 3D hexahedral solid-shell element, based on the initial work of Schwarze and Reese [2,3], which has shown promising results for the forming of thin isotropic materials [1], is extended for highly anisotropic materials. The advantages of a locking-free element formulation are shown through a comparison to commercially available solid and shell elements in forming simulations of a generic geometry. Additionally, first ideas for an approach of a membrane-bending-decoupling based on a Taylor approximation of the strain are discussed, which is necessary for an accurate description of the deformation behaviour of thin fabrics.

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A 3D Modelling Approach for Fluid Progression during Process Simulation of Wet Compression Moulding – Motivation & Approach

Cited by 11 publications

References 12 publications

Development of a Reactive Polyurethane Foam System for the Direct Sandwich Composite Molding (D-SCM) Process

Development of a Reactive Polyurethane Foam System for the Direct Sandwich Composite Molding (D-SCM) Process

Towards numerical prediction of flow-induced fiber displacements during wet compression molding (WCM)

Potential and challenges of a solid-shell element for the macroscopic forming simulation of engineering textiles

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