Finite element analysis and optimization of process parameters during stamp forming of composite materials

Venkatesan, Sudharshan; Kalyanasundaram, Shankar

doi:10.1088/1757-899x/10/1/012138

Cited by 6 publications

(7 citation statements)

References 13 publications

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“…The influence of parameters on the formability of composites was investigated by Venkatesan and Kalyanasundaram [11] who identified the preheat temperature as the most significant factor in controlling the formability of composites, followed by the blank holder force for achieving quality parts. Kalyanasundaram et al [12] studied the forming behavior of fiber metal laminates using the design of experiments technique, for understanding the effects of process parameters.…”

Section: Introductionmentioning

confidence: 99%

Investigation on influence of stamp forming parameters on formability of thermoplastic composite

Suresh

Kumar

2018

Polímeros

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Advanced fabric reinforced polymer composites find extensive applications in aerospace and structural fields due to their high mechanical properties. A novel stamp forming technique finds extensive use in the hemispherical forming of thermoplastic composites. This study investigates the influence of stamp forming parameters on the formability of thermoplastic composite using Taguchi's robust design and grey relational analysis. Taguchi's orthogonal array was used for designing the forming experiments. Responses such as forming ratio and logarithmic thickness strain were considered for the assessment of sheet formability through single and multi-response optimization. Analysis of variance was used for the determination of the contribution of each parameter on formability and it was identified that the die temperature acts as a prominent factor, followed by blank holder force and blank temperature. The confirmation test was conducted at optimum parameter levels and the obtained experimental grade was seen within the confidence interval of the predicted value.

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Section: Introductionmentioning

confidence: 99%

Investigation on influence of stamp forming parameters on formability of thermoplastic composite

Suresh

Kumar

2018

Polímeros

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“…Recent studies were conducted on the formability of thermoplastic composites using cupping tests. [14][15][16][17] It was found that forming rate, tool temperature, and sample holding force have the strongest effect on the structural behavior and the service life of products. Recently, studies conducted on the formability of thermosetting composites using cupping [18][19][20] and stretch bending tests 21 revealed that the composite shows sufficient ductility for press forming at elevated temperature (100°C).…”

Section: Introductionmentioning

confidence: 99%

Formability Characterization of Fiber Reinforced Polymer Composites Using a Novel Test Method

et al. 2021

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Fiber reinforced polymer composites are often used as a replacement for metal alloys because of the superior strength to weight ratio. However, a major drawback of these materials is the lack of formability caused by the low strain to failure ratio that does not allow the material to follow tooling contours into deep drawn shapes or tight radii. Composite materials have a multiscale hierarchical structure where micro and meso scale effects (fiber and tow scales) contribute to the macro structural response (laminate scale). In particular, during forming, different deformation occurs simultaneously at every scale. Currently, the amount of quantifiable and comparable forming data for both continuous and discontinuous fiber reinforced polymer composites, including a multi-scale understanding of the deformation response, is limited because of the lack of a testing system. This article proposes a novel test method and an apparatus called "the forming fixture" for testing the tow formability of fiber reinforced polymer composites by determining the required load to form an uncured resin impregnated fiber tow sample into a stretch drawn profile. Test results from forming of Hexcel (Stamford, CT) IM7-G continuous carbon fiber impregnated with Huntsman (The Woodlands, TX) RDM 2019-053 resin system, in the temperature range of 21°C-121°C, are discussed to demonstrate the use of the proposed apparatus including representative data. Results showed consistency and repeatability, validating the reliability of the novel method. The test aided in defining the forming behavior of the material in real time both visually (e.g. sample failure location) and as forming load versus displacement curves. A novel forming metrics, relating the maximum drawing depth with no failure and the maximum forming load, is defined to compare and select different fiber and resin formulations. Widespread adoption of the forming fixture will reduce reliance on a "trial and error" approach during the the forming process.

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“…For this purpose, Hooke's law is used, taking into consideration the determined sciENcE aNd tEchNology deformation values. The criteria for the destruction of composite materials are also commonly used [3,11,12,17,29].…”

Section: Introductionmentioning

confidence: 99%

“…More sophisticated methods include thermal imaging, ultrasonic, radiological and visual methods can be defined. [11,13,26,27,29].…”

Section: Introductionmentioning

confidence: 99%

Compression studies of multi-layered composite materials for the purpose of verifying composite panels model used in the renovation process of the freight wagon’s hull

Buchacz¹,

Baier²,

Herbuś³

et al. 2018

Eksploatacja i Niezawodność – Maintenance and Reliability

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The paper presents the procedure sequence for modelling multilayer composite materials using PLM Siemens NX software. Virtual studies were referring to three-point and four-point flexural test of composite material samples. Composite materials containing fiber reinforced epoxy resin composites were considered. Within the carried out research, a virtual experiment to test composite samples composed of 5, 7 and 10 layers was conducted. Then the virtual model was matched to the results obtained during the stationary tests. As a result of matching the composite material model to the real model, correct results of the virtual bending experiment of composite samples were obtained. The presented procedure sequence for modelling composite material was used to analyse the MES of the scaled side of the freight wagon. The modification consisted in the use of composite panels as reinforcing elements of the wagon’s hull from inside to extend its life. The presented modelling approach enabled the initial strength verification of the modified side of the freight wagon’s hull.

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Finite element analysis and optimization of process parameters during stamp forming of composite materials

Cited by 6 publications

References 13 publications

Investigation on influence of stamp forming parameters on formability of thermoplastic composite

Investigation on influence of stamp forming parameters on formability of thermoplastic composite

Formability Characterization of Fiber Reinforced Polymer Composites Using a Novel Test Method

Compression studies of multi-layered composite materials for the purpose of verifying composite panels model used in the renovation process of the freight wagon’s hull

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