A two-phase integrated flow-stress process model for composites with application to highly compressible phases

Niaki, Sina Amini; Forghani, Alireza; Vaziri, Reza; Poursartip, Anoush

doi:10.1016/j.mechmat.2017.03.016

Cited by 13 publications

(4 citation statements)

References 26 publications

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“…Over the years, composite process simulations have helped the industry to save large amounts of money by reducing the number of manufacturing trials. Simulation tools for forming [4][5][6][7][8][9], resin flow/ infusion [10][11][12][13][14][15][16][17], or cure simulation and residual stress prediction [18][19][20][21][22] are now an integrated part of the toolbox available to the composite designers. These, used together, allow accurate prediction for the occurrence of a large range of defect types.…”

Section: Introductionmentioning

confidence: 99%

Consolidation-Driven Defect Generation in Thick Composite Parts

Belnoue

Nixon-Pearson

Thompson

et al. 2018

Journal of Manufacturing Science and Engineering

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Fiber waviness is one of the most significant defects that occurs in composites due to the severe knockdown in mechanical properties that it causes. This paper investigates the mechanisms for the generation of fiber path defects during processing of composites prepreg materials and proposes new predictive numerical models. A key focus of the work was on thick sections, where consolidation of the ply stack leads to out of plane ply movement. This deformation can either directly lead to fiber waviness or can cause excess fiber length in a ply that in turn leads to the formation of wrinkles. The novel predictive model, built on extensive characterization of prepregs in small-scale compaction tests, was implemented in the finite element software ABAQUS as a bespoke user-defined material. A number of industrially relevant case studies were investigated to demonstrate the formation of defects in typical component features. The validated numerical model was used to extend the understanding gained from manufacturing trials to isolate the influence of various material, geometric, and process parameters on defect formation.

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Section: Introductionmentioning

confidence: 99%

Consolidation-Driven Defect Generation in Thick Composite Parts

Belnoue

Nixon-Pearson

Thompson

et al. 2018

Journal of Manufacturing Science and Engineering

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show abstract

“…Moreover, the complex interactions between textile, matrix, and air at both the micro and macro levels make their description difficult. While several authors presented three-phase models either for composite processing 25,26 or earth science, 27,28 these are single-scale flow models that cannot consider the impregnation of fiber bundles nor its influence on the matrix pressure. Models that consider dual scale flow 29,30 on the other hand typically do not consider textile compaction or the change of volume due to impregnation of fiber bundles.…”

Section: (A) (B)mentioning

confidence: 99%

A multiscale consolidation model for press molding of hybrid textiles into complex geometries

Werlen,

Rytka,

Dransfeld

et al. 2024

Polymer Composites

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Modeling the consolidation of fiber‐reinforced thermoplastic composites at the part level presents a formidable computational challenge due to the multi‐scale nature of the process. In this article, a method to bypass the multi‐scale problem by homogenizing the micro scale and describing the medium with characteristic parameters is described. The model is intended for press molding of hybrid textiles and considers a free‐form plate with non‐uniform thickness and can describe consolidation in three dimensions with some restrictions. 2D implementation in FEM shows how in‐plane matrix pressure gradients can arise in parts and cause fiber disorientation. Experimental verification demonstrates that fiber disorientation arises at the predicted location, and that defect size is proportional to matrix pressure gradient. This novel consolidation model provides new insights, enables part and process optimization, and paves the way for high‐quality composite part production.Highlights A consolidation model for press molding of hybrid textiles is presented. A method to extend consolidation models for complex geometry is presented. The origin of defect formation in complex geometries is explained.

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“…The approximated pressures from their model showed good agreement with their data and has been widely adopted by the scientific community. [15][16][17][18][19][20] The model described by Gutowski and Cai 13,14 in equation ( 1) only required three parameters: uncompacted fiber volume fraction (V o ), maximum packed fiber volume fraction (V a ), and effective fiber bed stiffness (A). However, their studies on fiber bed compaction were limited to fibers with a circular cross-section.…”

Section: Introductionmentioning

confidence: 99%

Extending the Gutowski model to kidney-bean and elliptically shaped fibers

Reichanadter

Månsson

2022

Journal of Composite Materials

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Efforts by manufacturers to produce more cost-effective carbon fibers have resulted in fibers with irregular cross-section often referred to as kidney-bean shaped fibers. In this research, compaction experiments were performed with a modified laser light section method to evaluate the compaction behavior of kidney-bean shaped carbon fibers. The kidney-bean shaped fibers followed a different compaction behavior compared to the Gutowski model for circular fibers. Additionally, these fibers required an order of magnitude larger force to compact than circular fibers to achieve similar fiber volume fraction, which has implications in infiltration and consolidation efficiency for composites manufacturing. A shape correction factor based on the fiber cross-sectional aspect ratio was proposed to extend the Gutowski model to fibers with irregular cross-sectional shapes. The modified Gutowski model provided an appropriate order of magnitude fit for the kidney-bean fibers. Furthermore, this modification to the Gutowski model recovered the original solution for circular fibers (cross-sectional aspect ratio = 1).

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A two-phase integrated flow-stress process model for composites with application to highly compressible phases

Cited by 13 publications

References 26 publications

Consolidation-Driven Defect Generation in Thick Composite Parts

Consolidation-Driven Defect Generation in Thick Composite Parts

A multiscale consolidation model for press molding of hybrid textiles into complex geometries

Extending the Gutowski model to kidney-bean and elliptically shaped fibers

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