A modular modeling approach for describing the in-plane forming behavior of unidirectional non-crimp-fabrics

Senner, Thomas; Kreissl, Sebastian; Merklein, Marion; Meinhardt, Josef; Lipp, Arnulf

doi:10.1007/s11740-014-0561-z

Cited by 13 publications

(3 citation statements)

References 13 publications

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“…This method is well suited for simple shaped parts like L-profiles, but becomes cumbersome for complex shaped parts. In case of the validation, the current study chooses a different approach based on a preceding draping simulation [24]. The information of fibre orientations is mapped from the draping simulation's 2D shell mesh to the 3D mesh of the distortion simulation.…”

Section: Modellingmentioning

confidence: 99%

Industrial Distortion Simulation of Fibre Reinforced Plastics – A Study on Finite Element Discretisation

Amann

Kreissl

Grass

et al. 2016

AMR

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Due to the occurrence of residual stresses during manufacturing, parts made of carbon fibre reinforced plastics exhibit considerable shape distortions. A finite element simulation tool to predict these distortions is developed in this work. All simulations are conducted using the finite element software LS-DYNA. For an L-profile, different finite element formulations are compared with regard to run time and accuracy. Having identical mesh topology, solid and thick shell elements show comparable run times and results. The layered composition of thick shells leads to a reduction of computational cost, but also increases the error concerning the predicted distortion angle. Finally, employing the insights gained from the mesh study, an actual car body part is studied for the purpose of validation.

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Section: Modellingmentioning

confidence: 99%

Industrial Distortion Simulation of Fibre Reinforced Plastics – A Study on Finite Element Discretisation

Amann

Kreissl

Grass

et al. 2016

AMR

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“…However, woven fabrics have so far mainly been the focus of research on macroscopic forming simulations [5,6] due to their better formability. In contrast, biaxial NCF [7][8][9][10] or UD-NCF [1,[11][12][13] have been investigated much less and mostly based on mesoscopic approaches [11,12], which can only be used to a limited extent for component forming simulations due to their high numerical effort. Nevertheless, they can predict local forming effects, while macroscopic approaches only capture the deformations mechanisms occuring on the meso-scale in a homogenized manner to indicate areas with a high likelihood of e.g.…”

Section: Introductionmentioning

confidence: 99%

Investigation of the Membrane Behavior of UD-NCF in Macroscopic Forming Simulations

Schäfer

Haas

Boisse

et al. 2022

KEM

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Unidirectional non-crimp fabrics (UD-NCF) provide an exceptionally high lightweight potentialcompared to other dry fabrics. However, their defect-free formability is limited compared towoven or biaxial fabrics due to their susceptibility to draping effects like wrinkling, gapping andfiber waviness. To predict these local effects and the global forming behavior efficiently, macroscopicmodelling approaches require the consideration of the mesoscopic material structure. A very detailedmacroscopic approach was proposed by Schirmaier et al. [1] and its prediction accuracy validatedwith qualitative and quantitative comparisons to component forming results. However, the approachcouples several deformation modes and therefore requires a very high number of inversely determinedmaterial parameters. In the present work a new macroscopic forming model for the membrane behaviorof UD-NCF is introduced based on superimposed shear, transverse tensile and perpendicular to thecarbon fiber tows oriented compressive strains. The model is parametrized with experimental resultsof different off-axis-tension-tests (OATs) (30°, 45° and 60°) and compared to the model proposed bySchirmaier et al. [1]. The results of the new membrane model agree well with the experimental andsimulative results in large areas, while utilizing a significantly reduced number of material parameters.However, some limitations are identified due to the reduced complexity of the model.

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“…It considers both large-strain deformation and non-linear constitutive behaviour. To account for the permanent deformation caused by irreversible slip between fibre yarns, stitching and glass fibres, an elastic-plastic material model is chosen to capture the experimentally observed non-linearity of the macroscopic stress-strain relation [11], [13], [16].…”

Section: Intr Introduction Oductionmentioning

confidence: 99%

Prediction of forming effects in UD-NCF by macroscopic forming simulation – Capabilities and limitations

Kärger¹,

Galkin²,

Kunze³

et al. 2021

Esaform 2021

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Unidirectional non-crimp fabrics (UD-NCF) provide the highest lightweight potential among dry textile materials. Compared to multiaxial NCF, the fabric layers in UD-NCF enable a more targeted tailoring. Compared to woven fabrics, the fibres of UD-NCF are straight without weakening undulations. However, the formability of UD-NCF is more challenging compared to woven fabrics. The yarns are bonded by a stitching and the deformation behaviour highly depends on this stitching and on the slippage between the stitching and the fibre yarns. Moreover, distinct local draping effects occur, like gapping and fibre waviness, which can have a considerable impact on the mechanical performance. Such local effects are particularly challenging or even impossible to be predicted by macroscopic forming simulation. The present work applies a previously published macroscopic UD-NCF modelling approach to perform numerical forming analyses and evaluate the prediction accuracy of forming effects. In addition to fibre orientations and shear angles, as investigated in previous work, the present work also provides indication for fibre area ratios, gapping, transverse compaction and fibre waviness. Moreover, the prediction accuracy is validated by comparison with experimental tests, where full-field strains of inner plies are captured by prior application of dots onto the fibre yarns, by measuring them via radiography and applying a photogrammetry software. The modelling approach provides good prediction accuracy for fibre orientations, shear strains and fibre area ratio. Conversely, normal fibre strains, indicating fibre waviness, and transverse strains, indicating gapping, show some deviations due to the multiscale nature of UD-NCF that cannot be captured entirely on macroscopic scale.

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A modular modeling approach for describing the in-plane forming behavior of unidirectional non-crimp-fabrics

Cited by 13 publications

References 13 publications

Industrial Distortion Simulation of Fibre Reinforced Plastics – A Study on Finite Element Discretisation

Industrial Distortion Simulation of Fibre Reinforced Plastics – A Study on Finite Element Discretisation

Investigation of the Membrane Behavior of UD-NCF in Macroscopic Forming Simulations

Prediction of forming effects in UD-NCF by macroscopic forming simulation – Capabilities and limitations

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