History and future of composites forming analysis

Akkerman, Remko; Haanappel, Sebastiaan; Sachs, Ulrich J.

doi:10.1088/1757-899x/406/1/012003

Cited by 12 publications

(11 citation statements)

References 38 publications

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“…Resin squeeze-out form in the regions of high fiber stress regions such as rounded edges and may lead to fiber breakage. 32 In blank type 3, in which the blank attached with eight springs both fiber directions, a balanced stress distribution is seen numerically in the net EOP, Figure 13a. As is expected, the maximum stress occurs in the lug regions.…”

Section: Resultsmentioning

confidence: 97%

Effects of gripper location and blank geometry on the thermoforming of a carbon-fiber woven-fabric/polyphenylene sulfide composite sheet

Atalay

Öztürk

2022

Journal of Thermoplastic Composite Materials

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The effects of gripper location and blank geometry on the thermoforming of a pre-consolidated carbon-fiber woven-fabric/polyphenylene sulfide (PPS) thermoplastic composite sheet (deformed into a U-beam geometry) are investigated both experimentally and numerically. The thermoforming experiments and simulations are performed at constant tool (160oC) and sheet (315oC) temperatures by using four thermoplastic composite blanks, which are different in geometry and inserted into the blank holder using gripping springs. Thermocouples are inserted on the composite sheet and forming molds in order to monitor the temperature variations during thermoforming. Thermoforming process is simulated in Ls-Dyna; the composite sheet is modeled using the Anisotropic Hyperelastic Material Model (MAT_249). An optimum punch speed and a spring constant are initially determined through numerical simulations. Afterward, the numerical thermoforming processes of four different blanks are implemented separately. Results reveal that the simulations show good agreements with the experiments in terms of defects formation and the maximum shear angles between the fiber directions on the final thermoformed U-beam geometry. When the blank is attached with eight springs from the lugs to the blank holder, the deformation and distortion of the net edge of the sheet are avoided, resulting in significant reductions in the extent of defect formation.

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Section: Resultsmentioning

confidence: 97%

Effects of gripper location and blank geometry on the thermoforming of a carbon-fiber woven-fabric/polyphenylene sulfide composite sheet

Atalay

Öztürk

2022

Journal of Thermoplastic Composite Materials

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“…In today's CFRTP component development, modeling and simulation of the forming process provides a powerful approach for defect prediction and verification, as well as optimization of manufacturability. To ensure accurate simulation results, material-specific input data are a basic prerequisite in addition to a suitable material modeling approach [7][8][9]. These material data must be determined under processing conditions.…”

Section: Introductionmentioning

confidence: 99%

“…During the forming process of composite laminates, several deformation mechanisms take place simultaneously. Bending, in-plane shear, and slippage (ply/ply interactions and tool/ply interactions) mechanisms can be classified as the three primary modes of deformation in UD composites that determine the forming result [9,12,13]. Moreover, simulation studies have shown that the temperature dependence of the composite material influences the geometric accuracy of the final component and that the bending rigidity plays a significant role in the formation of wrinkles [14][15][16].…”

Section: Introductionmentioning

confidence: 99%

Analysis of the Rotation Bending Test Method and Characterization of Unidirectional Carbon Fiber-Reinforced Polycarbonate Tapes at Processing Temperatures

Laresser,

Miron,

Kracalik

et al. 2024

Polymers

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Bending is one of the dominant material deformation mechanisms that occurs during the forming process of unidirectional (UD) thermoplastic tapes. Experimental characterization of the bending behavior at processing temperatures is crucial to obtaining close-to-reality data sets for process analysis or material modeling for process simulation. The main purpose of this study is to characterize to a high degree of accuracy the temperature-dependent bending behavior of single and multi-ply specimens of carbon fiber-reinforced polycarbonate (PC/CF) UD tapes at processing temperatures, which implies a molten state of the thermoplastic matrix. The application of the rotation bending test using a customized fixture may come with systematic deviations in the measured moment that result from a pivot offset or an effective clearance that is unknown under realistic test conditions. The present research analyzes these effects with analytical methods, experimental investigations, and simulations using a finite element model. In this context, a compensation method for the toe-in effect is evaluated. With this approach, we were able to obtain reliable data and characterize the bending resistance within the desired processing window. The data reveal a major drop in bending resistance between 200 °C and 250 °C and a less significant decrease between 250 °C and 300 °C. Analysis of the thickness-normalized bending resistances indicates a non-linear relationship between specimen thickness and measured moment but an increasing shear-dominated characteristic at higher temperatures.

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“…General purpose FE solvers have also been used to model the thermomechanical behaviour of thermoplastic composites -typically focused on shear characterisation of woven fabrics (organosheets) [29] [30]. Akkerman et al [31] presented a thorough review of composite forming simulations -highlighting the need to improve: the constitutive modelling, FE formulations and material characterisation techniques such that process-induced deformations can be accurately captured. The commonly used macro-scale models, which consider the material as an anisotropic continuum (typically using plate, membrane or shell elements), prevents smaller-scale features, like those discussed in [4], from being predicted.…”

Section: Introductionmentioning

confidence: 99%

Compaction behaviour of continuous fibre-reinforced thermoplastic composites under rapid processing conditions

Valverde

Belnoue

Kupfer

et al. 2021

Composites Part A: Applied Science and Manufacturing

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History and future of composites forming analysis

Cited by 12 publications

References 38 publications

Effects of gripper location and blank geometry on the thermoforming of a carbon-fiber woven-fabric/polyphenylene sulfide composite sheet

Effects of gripper location and blank geometry on the thermoforming of a carbon-fiber woven-fabric/polyphenylene sulfide composite sheet

Analysis of the Rotation Bending Test Method and Characterization of Unidirectional Carbon Fiber-Reinforced Polycarbonate Tapes at Processing Temperatures

Compaction behaviour of continuous fibre-reinforced thermoplastic composites under rapid processing conditions

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