Die-less forming of fiber-reinforced thermoplastic sheets and metal wire mesh

Rath, J.E.

doi:10.21741/9781644902417-5

Cited by 2 publications

(5 citation statements)

References 30 publications

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“…The used vacuum layups showed great potential to realize the temporary bond between the wire mesh and reinforcement material. In contrast to the observations made without bonding the organo sheet and wire mesh in [27], the materials deformed well together, and no detachment was observed. Furthermore, in contrast to connecting the glass fiber fabric to a wire mesh with adhesive in [24], the vacuum could directly support the following processing steps.…”

Section: Discussioncontrasting

confidence: 94%

“…One proposal is to use an alternative supporting material whose deformation behavior corresponds better to the draping mechanisms of woven reinforcement fibers while still providing stability to the flexible fabric. A possible solution would be the usage of metal wire mesh, as it shows the same draping mechanisms of out-of-plane bending and in-plane shear [27,28]. This paper elaborates on the process alternatives involving metal wire mesh and investigates the feasibility in practical forming experiments.…”

Section: Introductionmentioning

confidence: 99%

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Investigation of Metal Wire Mesh as Support Material for Dieless Forming of Woven Reinforcement Textiles

Rath,

Schüppstuhl

2023

JMMP

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Within the rapidly growing market for fiber-reinforced plastics (FRPs), conventional production processes involving molds are not cost-efficient for prototype and small series production. Therefore, new flexible forming techniques are increasingly being researched, many of which have been inspired by incremental sheet metal forming (ISF). Due to the different deformation mechanisms of woven reinforcement fibers and metal sheets, ISF is not directly applicable to FRP. Instead, shear and bending of the fibers need to be realized. Therefore, a new dieless forming process for the production of FRP supported by metal wire mesh as an auxiliary material is proposed. Two standard tools, such as hemispherical punches, are used to locally bend a reversible layup of metal wire mesh and woven reinforcement fiber fabric enclosed in a vacuum bag. Therefore, the mesh aids in introducing shear into the material due to its ability to transmit compressive in-plane forces, and it ensures that the otherwise flexible fabric maintains the intended deformation until the part is cured or solidified. Basic experiments are conducted using thermoset prepreg, woven commingled yarn fabric, and thermoplastic organo sheets, proving the feasibility of the approach.

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Section: Discussioncontrasting

confidence: 94%

Section: Introductionmentioning

confidence: 99%

Investigation of Metal Wire Mesh as Support Material for Dieless Forming of Woven Reinforcement Textiles

Rath,

Schüppstuhl

2023

JMMP

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“…Similarly, the wire mesh would allow global impregnation, consolidation and solidification, for example, in a vacuum setup, after forming. As presented in [41], metal mesh support can be used for organo sheet-forming as well, with possibilities to realize electrical resistance heating through the wires.…”

Section: Discussion and Outlookmentioning

confidence: 99%

“…In the latter case, at least the starting point of the draping needs to be firmly connected to the auxiliary material for determined draping. A feasible auxiliary material could be metal wire mesh, as it possesses the same deformation mechanisms as woven textiles, which are bending and shear [41].…”

Section: Fixation Of the Fabricmentioning

confidence: 99%

“…The setup was then centrally clamped between two poles, as depicted in Figure 14a. During evaluation of dieless wire mesh forming in [41], we found that the layering strategy is most suitable, as lower forming force is required and (discontinuous) forming is more symmetric compared to the path-forming strategy. Therefore, dieless forming with two handheld steel tools with hemispherical tips, shown in Figure 14b, was performed according to the discontinuous layering strategy approach.…”

Section: Pre-impregnated Thermoset 421 Setupmentioning

confidence: 99%

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Processing Strategies for Dieless Forming of Fiber-Reinforced Plastic Composites

Graupner

Schüppstuhl

2023

Machines

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The demand for lightweight materials, such as fiber-reinforced plastics (FRP), is constantly growing. However, current FRP production mostly relies on expensive molds representing the final part geometry, which is not economical for prototyping or highly individualized products, such as in the medical or sporting goods sector. Therefore, inspired by incremental sheet metal forming, we conduct a systematic functional analysis on new processing methods for shaping woven FRP without the use of molds. Considering different material combinations, such as dry fabric with thermoset resin, thermoset prepreg, thermoplastic commingled yarn weave and organo sheets, we propose potential technical implementations of novel dieless forming techniques, making use of simple robot-guided standard tools, such as hemispherical tool tips or rollers. Feasibility of selected approaches is investigated in basic practical experiments with handheld tools. Results show that the main challenge of dieless local forming, the conservation of already formed shapes while allowing drapability of remaining areas, is best fulfilled by local impregnation, consolidation and solidification of commingled yarn fabric, as well as concurrent forming of prepreg and metal wire mesh support material. Further research is proposed to improve part quality.

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Die-less forming of fiber-reinforced thermoplastic sheets and metal wire mesh

Cited by 2 publications

References 30 publications

Investigation of Metal Wire Mesh as Support Material for Dieless Forming of Woven Reinforcement Textiles

Investigation of Metal Wire Mesh as Support Material for Dieless Forming of Woven Reinforcement Textiles

Processing Strategies for Dieless Forming of Fiber-Reinforced Plastic Composites

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