Mechanisms of Origin and Classification of Out-of-Plane Fiber Waviness in Composite Materials—A Review

Thor, Michael; Sause, Markus G. R.; Hinterhölzl, Roland

doi:10.3390/jcs4030130

Cited by 76 publications

(39 citation statements)

References 137 publications

(247 reference statements)

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“…Currently, there is no unanimously accepted terminology and consistent use for the differentiation between waves, wrinkles, folds, undulations, and misalignments, as illustrated in Figure 3. However, according to Thor et al [47], the definition is constructed for the sake of clarity to the reader. The effect of manufacturing in polymer composite parts that results in decreased mechanical performance is usually due to the ply/fiber waviness or wrinkling conditions.…”

Section: Misaligned Fibersmentioning

confidence: 99%

Delamination and Manufacturing Defects in Natural Fiber-Reinforced Hybrid Composite: A Review

et al. 2021

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In recent years, most boat fabrication companies use 100% synthetic fiber-reinforced composite materials, due to their high performance of mechanical properties. In the new trend of research on the fabrication of boat structure using natural fiber hybrid with kevlar/fiberglass-reinforced composite, the result of tensile, bending, and impact strength showed that glass fiber-reinforced polyester composite gave high strength with increasing glass fiber contents. At some point, realizing the cost of synthetic fiber is getting higher, researchers today have started to use natural fibers that are seen as a more cost-effective option. Natural fibers, however, have some disadvantages, such as high moisture absorption, due to repelling nature; low wettability; low thermal stability; and quality variation, which lead to the degradation of composite properties. In recent times, hybridization is recommended by most researchers as a solution to natural fiber’s weaknesses and to reduce the use of synthetic fibers that are not environmentally friendly. In addition, hybrid composite has its own special advantages, i.e., balanced strength and stiffness, reduced weight and cost, improved fatigue resistance and fracture toughness, and improved impact resistance. The synthetic–nature fiber hybrid composites are used in a variety of applications as a modern material that has attracted most manufacturing industries’ attention to shift to using the hybrid composite. Some of the previous studies stated that delamination and manufacturing had influenced the performance of the hybrid composites. In order to expand the use of natural fiber as a successful reinforcement in hybrid composite, the factor that affects the manufacturing defects needs to be investigated. In this review paper, a compilation of the reviews on the delamination and a few common manufacturing defect types illustrating the overview of the impact on the mechanical properties encountered by most of the composite manufacturing industries are presented.

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Section: Misaligned Fibersmentioning

confidence: 99%

Delamination and Manufacturing Defects in Natural Fiber-Reinforced Hybrid Composite: A Review

et al. 2021

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“…When flat ply shapes are draped over complex curved mold geometries, fiber angles can be locally skewed due to wrinkling of the ply. These fiber angle deviations are known as fabric shear [29]. During draping, the direction of fiber tows within the unidirectional tape can be locally altered.…”

Section: Materials Orientation Thickness Ply Draping and Partitioningmentioning

confidence: 99%

Cost, Draping, Material and Partitioning Optimization of a Composite Rail Vehicle Structure

Lang

Radford

2022

Materials

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This study proposes a novel methodology to combine topology optimization and ply draping simulation to partition composite structures, improve structural performance, select materials, and enable more accurate representations of cost- and weight-efficient manufacturable designs. The proposed methodology is applied to a structure as a case study to verify that the methodology is effective. One design concept is created by subjecting the structure to a kinematic ply draping simulation to inform the partitioning of the structure, improve drapability and performance, and reduce structural defects. A second design concept is created that assumes that plies are draped over the entire structural geometry, forming an integral design. The two design concepts’ topologies are subsequently optimized to specify ideal material and ply geometries to minimize mass and reduce costs. The results indicate that the partitioned structure has a 19% lower mass and 15% lower material costs than the integral design. The two designs produced with the new methodology are also compared against two control designs created to emulate previously published methodologies that have not incorporated ply draping simulations. This demonstrates that neglecting the effects of ply draping produces topology optimization solutions that under-predict the mass of a structure by 26% and costs by 38%.

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“…These defects influence the fiber distribution and orientation in the structure and lead to local variability of the fiber density and thus areas rich in resin after injection. This heterogeneity affects directly the mechanical properties which depend strongly on the fiber direction, orientation and density [58] [59]. For the fabric, not only rotation is allowed under strain but also an in-plane sliding displacement between the yarn/filament of the fabric.…”

Section: B) In-plane Deformationmentioning

confidence: 99%

Composite preforming defects: a review and a classification

2021

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Advancing in the process of extending the use of composites for structural parts applications, it is inevitable to work on complex shapes. That is the main reason why understanding the complex forming mechanisms and the factors put into play during the process of composite materials is a major interest for both pre-impregnated forming and dry fabric preforming. Thus, the apdpearance of defects is a major concern and predicting their appearance for optimal product quality is the priority. A great number of authors showed that defects degrade the overall performance of the composite by creating local heterogeneities. Many factors can initiate these defects. This article is an assembly of the development of the literature on this subject. It is an attempt to provide a description for each defect and a classification order following the scale, the behavior mechanisms, the appearance plan. This will help to converge toward an identification of the defects manifesting during the composite forming.

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Mechanisms of Origin and Classification of Out-of-Plane Fiber Waviness in Composite Materials—A Review

Cited by 76 publications

References 137 publications

Delamination and Manufacturing Defects in Natural Fiber-Reinforced Hybrid Composite: A Review

Delamination and Manufacturing Defects in Natural Fiber-Reinforced Hybrid Composite: A Review

Cost, Draping, Material and Partitioning Optimization of a Composite Rail Vehicle Structure

Composite preforming defects: a review and a classification

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