A 2D modeling approach for fluid propagation during FE-forming simulation of continuously reinforced composites in wet compression moulding

Poppe, Christian; Dörr, Dominik; Henning, Frank; Kärger, Luise

doi:10.1063/1.5034823

Cited by 13 publications

(14 citation statements)

References 8 publications

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“…Wet compression moulding (WCM) provides high-volume production potential for continuous fibre-reinforced components. Due to simultaneous draping, infiltration and curing (viscous draping), low cycle times can be achieved [1][2][3]. The investigated thermoset-based WCM process consists of five process steps ( Fig.…”

Section: Introductionmentioning

confidence: 99%

“…Consequently, key knowledge on the mutual physical dependencies within the viscous draping stage can be achieved using infiltration dependent material models with negligence of the fluid pressure. This is an adequate assumption since the fluid pressure mainly increases within the last 10 percent of the tool stroke, when draping is almost completed [2]. Consequently, knowledge on the mutual physical dependencies provides the foundation for advanced process simulation methods, which enable lean and purposive process development and part design.…”

Section: Introductionmentioning

confidence: 99%

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Comparative experimental and numerical analysis of bending behaviour of dry and low viscous infiltrated woven fabrics

Poppe

Rosenkranz

Dörr

et al. 2019

Composites Part A: Applied Science and Manufacturing

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Wet compression moulding (WCM) provides high-volume production potential for continuous fibre-reinforced composite components via simultaneous draping and infiltration. Experimental and theoretical investigations proved strong mutual dependencies between resin flow and fabric deformation, which are not fully understood yet. This limits development of suitable process simulation methods and applies in particular for the characterisation of infiltrated bending behaviour-essential for an accurate prediction of draping effects. Therefore, a comparative characterisation of the bending behaviour of dry and infiltrated woven fabrics is presented using a modified cantilever and a rheometer bending test. Experimental results reveal both, rate-and viscosity-dependencies. A comparison of the quantitative results exposed an explicable systematic deviation between the two tests, whereas qualitative results are comparable. Finally, Finite Element forming simulations, comprising two bending models corresponding to cantilever and rheometer test are performed to evaluate the experimental findings on component level.

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Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Comparative experimental and numerical analysis of bending behaviour of dry and low viscous infiltrated woven fabrics

Poppe

Rosenkranz

Dörr

et al. 2019

Composites Part A: Applied Science and Manufacturing

Self Cite

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“…The implemented hyperviscoelastic formulation is based on in variants of the Green Lagrange strain tensor E and the rate of de formation tensor D. Two deformation modes, elongation in both fibre directions and shear, are taken into account and thus contribute to the potential of free energy Ψ given by P1 e e end (5) with the polynomial coefficients k i P1 .…”

Section: Constitutive Equations For Membrane Behaviourmentioning

confidence: 99%

“…This includes the impact of infiltration on the draping behaviour, as well as the effect of higher fluid pressures superimposed to the forces during draping. This impedes a comprehensive and physical based understanding of the above outlined interactions and thus limits the development of rea sonable process simulation methods for the WCM process [1,5].…”

Section: Introductionmentioning

confidence: 99%

“…The stack is simulta neously draped and fully impregnated within the next process step (4), which is called viscous draping. The part can be demoulded when shape stability is reached, which is determined by the curing velocity of the resin (5). Since significant cavity pressures develop only towards the end of the tool stroke, the influence of resin on the draping is mainly limited to the intra ply and interface behaviour.…”

Section: Introductionmentioning

confidence: 99%

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Experimental and numerical investigation of the shear behaviour of infiltrated woven fabrics

Poppe

Dörr

Henning

et al. 2018

Composites Part A: Applied Science and Manufacturing

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Wet compression moulding (WCM) as a promising alternative to resin transfer moulding (RTM) provides highvolume production potential for continuously fibre reinforced composite components. Lower cycle times are possible due to the parallelisation of the process steps draping, infiltration and curing during moulding. Although experimental and theoretical investigations indicate a strong mutual dependency arising from this parallelisation, no material characterisation setups for textiles infiltrated with low viscous fluids are yet available, which limits a physical-based process understanding and prevents the development of proper simulation tools. Therefore, a modified bias-extension test setup is presented, which enables infiltrated shear characterisation of engineering textiles. Experimental studies on an infiltrated woven fabric reveal both, rateand viscosity-dependent shear behaviour. The process relevance is evaluated on part level within a numerical study by means of FE-forming simulation. Results reveal a significant impact on the global and local shear angle distribution, especially during forming.

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Advances in composite forming through 25 years of ESAFORM

et al. 2022

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The increase in the number of structural applications of composite materials, especially in the aerospace and automotive industries, has led to a demand for robust models to simulate composite forming processes. The mechanical behaviour of composite materials during forming is relatively complex due to their fibre-matrix composition. Many research studies have been conducted in the past 25-plus years into experimental methods for the characterization of the mechanical behaviours that are exhibited by textile-reinforced composite material systems during forming and into the development of material models to be used in computer codes for forming simulations. These studies have been presented and discussed in the ESA-FORM conferences since 1997 and especially in the 'Composite Forming Processes' mini-symposium launched in 2001. This article presents a survey of the research carried out in this context. Mechanical characterization tests specific to composite forming are presented as well as recent analysis techniques such as digital image correlation and X-ray tomography. Threedimensional mechanical behaviour laws, in particular hypo-and hyperelastic, have been developed and extended to second gradient models. Specific shell approaches have been presented and their application to wrinkling analysis. Resin flow and permeability analysis is another area of research in composite forming processes which are discussed in this article. Research on certain processes is also presented, in particular thermoforming of thermoplastic composites, wet compression moulding, pultrusion, automated fibre placement and three-dimensional printing. This comprehensive review of the works of multiple research groups is a recognition of the breadth and depth of efforts that have been invested into the understanding of the manufacturability of textile-reinforced composite materials.

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A 2D modeling approach for fluid propagation during FE-forming simulation of continuously reinforced composites in wet compression moulding

Cited by 13 publications

References 8 publications

Comparative experimental and numerical analysis of bending behaviour of dry and low viscous infiltrated woven fabrics

Comparative experimental and numerical analysis of bending behaviour of dry and low viscous infiltrated woven fabrics

Experimental and numerical investigation of the shear behaviour of infiltrated woven fabrics

Advances in composite forming through 25 years of ESAFORM

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