Consolidation Modeling during Thermoforming of Thermoplastic Composite Prepregs

Xiong, Hu; Hamila, Nahiene; Boisse, Philippe

doi:10.3390/ma12182853

Cited by 38 publications

(19 citation statements)

References 92 publications

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“…In this modeling approach, the transverse compaction of the layers is not considered. This would require the use of 3D finite elements or solid-shell elements [73][74][75]. In the present study, these stress resultant shells were used efficiently to simulate composite laminate wrinkling during bending and the associated ply separation (up to 100 layers).…”

Section: Stress Resultant Shell Approachmentioning

confidence: 99%

Simulation of Wrinkling during Bending of Composite Reinforcement Laminates

et al. 2020

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When a thick laminate is subjected to bending, under certain boundary conditions, wrinkles may appear and develop due to the inextensibility of the fibers. Wrinkling is one of the most critical defects in composite manufacturing. Numerical simulation of the onset and growth of such wrinkles is an important tool for defining optimal process parameters. Herein, several bending experiments of thick laminates are presented. They were found to lead to severe wrinkling and delamination of different kinds. It is shown that the history of loading changed the developed wrinkles. Stress resultant shell finite elements specific to textile reinforcement forming show their relevance to provide, for these wrinkles induced by bending, results in good agreement with the experiments, both with regard to the onset of the wrinkles and to their development. This numerical approach was used to improve the understanding of the phenomena involved in wrinkling and to define the conditions required to avoid it in a given process.

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Section: Stress Resultant Shell Approachmentioning

confidence: 99%

Simulation of Wrinkling during Bending of Composite Reinforcement Laminates

et al. 2020

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“…The same analysis was conducted by Lee et al (2010) using a glass fiber plain reinforced polypropylene [21] and by Khan et al (2010) [22]. The curvatures of the Double Dome are suitable to verify the shear behavior of thermoplastic composites during the thermoforming process and all its consequences on the final surface quality, as stated by Xiong et al (2019) [23]. Komeili and Milani (2016) also used the Double Dome shape in order to study the effect of shear tension coupling in forming simulation of woven fabric reinforcements [24].…”

Section: Of 26mentioning

confidence: 97%

Validation of a Simulation Methodology for Thermoplastic and Thermosetting Composite Materials Considering the Effect of Forming Process on the Structural Performance

et al. 2020

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This research work investigated the influence of the press molding manufacturing process on the mechanical properties, both for thermoplastic and thermosetting fiber reinforced composite materials. The particular geometry of the case study, called Double Dome, was considered in order to verify the behavior of the Thermoplastic and Thermosetting prepreg in terms of shell thickness variation and fibers shear angle evolution during the thermoforming process. The thermoforming simulation was performed using LS-DYNA® Finite Element Analysis (FEA) code, and the results were transferred by Envyo®, a dedicated mapping tool, into a LS-DYNA® virtual model for the structural simulation. A series of Double Dome specimens was produced with industrial equipment, and a bending experimental test was been carried on. Finally, a numerical-experimental correlation was performed, highlighting a significant forecast of the mechanical properties for the considered component.

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“…In transverse compression, the response of the fibrous material is driven by the fiber network rearrangement as well as fiber-tofiber contacts (Xiong et al, 2019). Recalling that we consider double-membrane forming processes where the individual layers of the stack are compacted along thickness direction (E 3 ) before forming, compression behavior understanding appears to be of prime importance.…”

Section: Tensions and Compressionsmentioning

confidence: 99%

A Contribution to the Study of the Forming of Dry Unidirectional HiTape® Reinforcements for Primary Aircraft Structures

Bouquerel¹,

Moulin

Drapier

2021

Front. Mater.

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In the context of developing competitive liquid composites molding processes for primary aircraft structures, modeling the forming stage of automatically-placed initially flat stacks of dry reinforcements is of great interest. In the case of HiTape®, a dry unidirectional carbon fiber reinforcement designed to achieve performances comparable to state-of-the-art pre-impregnated materials, the presence of a thermoplastic veil on each side of the material for both processing and mechanical purposes should also be considered when modeling forming in hot conditions. As a dry unidirectional reinforcement, HiTape® is expected to exhibit a transversely isotropic behavior. Computation cost and strong characterization challenges led us to model its behavior at the forming process temperature (above the thermoplastic veil melting temperature) through a homogeneous equivalent continuous medium exhibiting four ‘classical’ deformation modes and a specific structural mode, namely out-of-plane bending. The response of both single plies and stacks of HiTape® to this latter structural mode was characterized at the forming process temperature using a modified Peirce flexometer. Results on single plies showed a non-linear softening moment-curvature behavior and a corresponding flexural stiffness much lower than what can be inferred from continuum mechanics. Moreover, testing stacks revealed that the veil acts as a thin load transfer layer between the plies undergoing relative in-plane displacement, i.e. inter-ply sliding. This inter-ply response was then characterized separately at the forming process temperature thanks to a specific method relying on a pull-through test. Experiments performed at pressures and speeds representative of the forming stage revealed that a hydrodynamic lubricated friction regime predominates, i.e. a linearly increasing relationship between the friction coefficient and the modified Hersey number. From an industrial point of view, high forming pressures and low speeds are therefore recommended to promote inter-ply slip to limit the occurrence of defects such as wrinkles.

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Consolidation Modeling during Thermoforming of Thermoplastic Composite Prepregs

Cited by 38 publications

References 92 publications

Simulation of Wrinkling during Bending of Composite Reinforcement Laminates

Simulation of Wrinkling during Bending of Composite Reinforcement Laminates

Validation of a Simulation Methodology for Thermoplastic and Thermosetting Composite Materials Considering the Effect of Forming Process on the Structural Performance

A Contribution to the Study of the Forming of Dry Unidirectional HiTape® Reinforcements for Primary Aircraft Structures

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