Single Layered Dry Fabric Forming Simulation by Finite Element Analysis

Abstract

Automakers are gradually using more carbon fiber reinforced plastic (CFRP) in mass production cars because the developments of resin transfer molding (RTM) have reduced its cycle time to less than 10 minutes. Carbon fabrics are usually used as a reinforcement in RTM. First, dry carbon fabric is placed between forming dies. Then resin is injected into the preformed dry fabric and cured to create the final composite part. It is well known that the performance of the final composite part strongly depends on changes in fiber orientation during the process. Moreover wrinkles and fiber failures are major defects which occur during processes so that preforming process simulation is very important to predict fiber orientation and forming defects.Compressive and bending properties play important roles in describing wrinkles. However, many of existing researches do not consider these effects in the simulation models. In the present study, we propose a model for finite element analysis that can consider compressive and bending properties as well as tensile and shear properties of dry fabric. We conduct the hemispherical preforming simulation and verify the proposed model by comparing the results to those of meso-scale modeling model in order to showcase the capability of the method for evaluating wrinkles, fiber failures, and changes in fiber orientation.

FE Analysis of the Influence of Fiber Orientation to Shearing and Wrinkling of Fiber Reinforced Thermoplastic Parts

“…11). [11] investigate the influence of fiber orientation to the bending stiffness with a meso-scale model of a fabric. FE analysis with the meso-scale model also show significant decrease of the bending stiffness if the yarns have an angle of ±45°.…”

Temperature-Dependent modelling of tension, in-Plane shear, and bending behaviour in non-isothermal thermo-Stamping process simulation of unidirectional UHMWPE fibre reinforced thermoplastic TPU composites

“…[6][7][8] It has been demonstrated that modelling the bending stiffness of fabric or molten thermoplastic prepregs with conventional shell theories in commercial software is unrealistic. [8][9][10] Consequently, more accurate methods that include the bending stiffness in forming modelling are currently a key research area in the forming simulation of CoFRTP. [11][12][13][14] Furthermore, it is essential to consider the thermal-dependence characteristics in the thermo-stamping process modelling because the temperature distribution might not be uniform in the blank during the forming process.…”