A benchmark study of the material models for forming simulation of woven fabrics

Yildirim, Halil; Öztürk, Fahrettin

doi:10.1080/00405000.2021.1914409

Cited by 5 publications

(4 citation statements)

References 18 publications

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“…In a previous study, the shear responses of punched loose plain weave fabrics were simulated in Ls-Dyna in order to evaluate the prediction capabilities of the fabric models including Viscoelastic Loose Fabric (MAT_234), Micromechanics Dry Fabric Model (MAT_235), and Anisotropic Hyperelastic Model (MAT_249). 10 Among above, the Anisotropic Hyperelastic Model agreed the most with the experiments when the outer contour and shear angle distribution of punched fabrics were considered. In another study, a fully automated forming process of continuous fiber reinforced thermoplastics was simulated in Ls-Dyna under various scenarios in order to prevent wrinkling and fracture.…”

Section: Introductionsupporting

confidence: 52%

“…Springs were used to induce in-plane tension in the composite sheet with an intent of minimizing wrinkles. [5][6][7][8][9][10][11][12][13][14][15][16][17] The punch, die, and frame were assumed rigid and modeled using MAT-RIGID (MAT-20) material model. Since the assigned rigid material elements were not taken into account in the program algorithm and hence have no stored historical data, it is cost-effective.…”

Section: Numerical Simulationsmentioning

confidence: 99%

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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: Introductionsupporting

confidence: 52%

Section: Numerical Simulationsmentioning

confidence: 99%

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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“…MAT_249 is a material model in which the matrix and fabric are formulated as thermal elasto-plastic and anisotropic hyperelastic materials, respectively. In MAT_249 the combined stress response, σ, is obtained by the superposition of the stresses in the matrix, σ m , and fabric, σ f , as follows [34]:…”

Section: Finite Element Simulationmentioning

confidence: 99%

Effects of spring gripper configuration and forming temperature on the thermo-stamping of a carbon-fiber woven-fabric/polyphenylene sulfide composite sheet

Yildirim

Uren

Öztürk

2023

Meas. Sci. Technol.

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Although thermo-stamping is one of the fastest and most cost-effective processes in the production of fabric-reinforced thermoplastic composite parts used in aerospace and automotive industries, it is quite prone to result in many defects. In particular, wrinkling is a frequently encountered defect in the production of doubly curved parts and is very sensitive to process parameters. Finite element analysis (FEA) is an effective tool for estimating defects that can occur during the thermo-stamping process. In this study, effects of spring configurations in spring-based holders and forming temperature on wrinkling and shear deformation are investigated experimentally and numerically by using two different spring configurations and three different forming temperatures. Non-isothermal and isothermal approaches used in thermo-stamping simulations are compared in terms of wrinkling estimation, and shear angle distribution. The results reveal that while the wrinkle predictions obtained by the non-isothermal approach are in good agreement with the experimental results, the isothermal approach cannot predict any of the wrinkles obtained in the experiment. Furthermore, the obtained results confirm that spring gripper configurations and forming temperature have a significant effect on wrinkling and shear angle distribution.

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“…MAT_249 and MAT_293 are the latest models to simulate such processes in LS DYNA. The success of MAT_249 in terms of prediction capability has been tested in previous studies [2][3][4]. However, the suitability of MAT_293 for forming simulations of dry fabrics needs to be tested.…”

Section: Introductionmentioning

confidence: 99%

Simulation of the hemispherical forming process of a woven fabric with two different material models

Yildirim¹

2022

acperpro

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The anisotropic hyperelastic model (MAT_249) and Non-Orthogonal Model (MAT_293) are the material models developed recently to simulate the forming process of dry fabric and fabric-reinforced thermoplastic prepregs. In this study, the prediction capabilities of these two models in terms of shear angle distribution and boundary profile of the deformed fabric are compared over a hemispherical forming simulation of a plain weave E-glass fabric reinforcement. According to the results, in the simulation performed with MAT_293, it is seen that excessive distortions occur in the meshes at the advanced stages of the deformation in the fabric. In addition, after a certain punch stroke, the shear angle distribution obtained with MAT_293 starts to deviate rapidly from realistic results. MAT_249 produces consistent results even in large deformations.

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A benchmark study of the material models for forming simulation of woven fabrics

Cited by 5 publications

References 18 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

Effects of spring gripper configuration and forming temperature on the thermo-stamping of a carbon-fiber woven-fabric/polyphenylene sulfide composite sheet

Simulation of the hemispherical forming process of a woven fabric with two different material models

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