Forming of advanced thermoplastic tailored blanks
Using a multi-scale modelling approach, implemented in a powerful commercial finite element code, accurate forming simulations for thermoplastic composites and thermosetting prepregs can be conducted. Coupling micro mechanical models, based on fibre volume fraction and matrix rheology [1-2], to a non-orthogonal constitutive model [3], the aim is to predict both the fibre direction after forming and the occurrence of any potential defects such as wrinkling, gaps or tearing of the sheet [4]. Use of unidirectional plies means that the initial blank can be tailored with fibre directions placed in optimum directions. Ultimately the predictions of manufacturing defects and fibre directions after forming will feed into structural simulations of composite parts.
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[1] Harrison, P., Clifford, M.J., Long, A.C. and Rudd, C.D. (2004) A constituent-based predictive approach to modelling the rheology of viscous textile composites. Composites Part A: Applied Science and Manufacturing, 35(7-8), pp. 915-931. (doi: 10.1016/j.compositesa.2004.01.005)
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[2] Harrison, P. , Yu, W.-R. and Long, A.C. (2011) Rate dependent modelling of the forming behaviour of viscous textile composites. Composites Part A: Applied Science and Manufacturing, 42(11), pp. 1719-1726. (doi: 10.1016/j.compositesa.2011.07.026)
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[3] Yu, W.-R., Harrison, P. and Long, A. (2005) Finite element forming simulation for non-crimp fabrics using a non-orthogonal constitutive equation. Composites Part A: Applied Science and Manufacturing, 36(8), pp. 1079-1093. (doi: 10.1016/j.compositesa.2005.01.007)
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[4] Harrison, P. , Gomes, R. and Curado-Correia, N. (2013) Press forming a 0/90 cross-ply advanced thermoplastic composite using the double-dome benchmark geometry.Composites Part A: Applied Science and Manufacturing, 54, pp. 56-69. (doi: 10.1016/j.compositesa.2013.06.014)
