Computer simulation of thermoforming process and its verification using a rapid tooling mould

Modławski, M.; Jaruga, T.

doi:10.1051/matecconf/201815702032

Cited by 7 publications

(5 citation statements)

References 3 publications

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“…Thermostamping of fiber-reinforced thermoplastic composites is growing in the aerospace and automotive industries due to low cycle times and recyclability [1][2][3]. Instead of doing a lot of trial and error experiments, a computer simulation offers a more efficient way of finding suitable combinations of thermostamping parameters that would result in high quality parts [4]. In this paper, thermostamping process of a thermoplastic composite stringer is simulated using the finite element analysis software AniForm™.…”

Section: Introductionmentioning

confidence: 99%

Thermostamping Simulation of a Carbon Fiber-Reinforced PAEK Composite Stringer

Haris,

Cheah,

Teo

2024

SSP

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The results of thermostamping simulation of a composite stringer demonstrator made from a high temperature plastic (PAEK) reinforced with 5-Harness Satin (5HS) weave carbon fiber fabric are presented in this paper. The effects of four different gripping configurations (A, B, C and D) and four different laminate layups ([0f]4 cross-ply, [45f]4 angle-ply, [0f/45f]s and [45f/0f]s quasi-isotropic layups) on the quality of the formed part are computationally investigated using AniForm™ software. The gripping configuration A consists of 22 pieces of extension spring with stiffness of 0.17 N/mm and pretension of 5.50 N. The configuration B consists of 8 pieces of extension spring with stiffness of 0.51 N/mm and pretension of 16.25 N. The configuration C uses the same type of spring as used in the configuration B, only its quantity is more (12 pieces). The configuration D is similar to the configuration C but they are different in the spring arrangement. Our simulation results show that regardless of the gripping configuration the quasi-isotropic layups demonstrate the lowest laminate sag while the angle-ply layup demonstrates the highest shear angle and thickness. For the slip-path length, it strongly depends on the layup and gripping configuration. As conclusion, the optimal choices for the thermoformed composite stringer demonstrator are cross-ply layup with configuration C, angle-ply layup and [45f/0f]s quasi-isotropic layup with configuration D, and [0f/45f]s quasi-isotropic layup with configuration B.

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Section: Introductionmentioning

confidence: 99%

Thermostamping Simulation of a Carbon Fiber-Reinforced PAEK Composite Stringer

Haris,

Cheah,

Teo

2024

SSP

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“…This was followed by several contributions which provided a good understanding of the sheet deformation mechanisms and their influence on the resulting wall-thickness profile of parts with distinct geometries (e.g. Crawford and Lui 1982;DeLorenzi and Nied 1987;Kouba et al 1992;Song et al 1991Song et al , 1992Modławski and Jaruga 2018;Warby et al 2003). For example, during vacuum forming of a cylindrical cup, a free bubble with a thickness gradient from its base to the pole is initially created; then, it progresses downwards while contacting the lateral (and later the bottom) cold mold surface, which causes its quick solidification.…”

Section: Introductionmentioning

confidence: 99%

Improving the thickness distribution of parts with hybrid thermoforming

Duarte

Ribeiro

Ferreira

et al. 2022

International Polymer Processing

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With the aim of improving the thickness gradient of thermoformed parts, and thus increase their performance and/or reduce their weight, the concept of hybrid thermoforming is introduced, whereby local thickness differences in extruded sheets are created prior to thermoforming. Material is removed by CO2 ablation or 3D printing of an over-thickness at specific locations of sheets previously extruded. The feasibility and potential usefulness of the approach is explored experimentally for the production of a truncated conical cup, since this is a well-characterized application. The conventional thickness distributions obtained by conventional vacuum forming are significantly changed with the new strategy and can be tuned by adequately selecting the locations and amount of material do be removed and/or added.

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“…The temperature distribution can be controlled to build non-uniform conditions by zone-heating to prevent the thinner corners under uniform temperature profile [ 15 , 16 ]. The numerical approach by finite element analysis (FEA) offered a way to achieve process modelling of thermoforming validated by the experimental tests [ 17 , 18 , 19 , 20 , 21 ], which helped optimise the operation by virtual testing to improve the traditional trial-and-error method [ 17 , 18 , 19 ]. The temperature could be easily implemented into FEA modelling to perform process simulation at non-uniform or non-isothermal conditions [ 22 , 23 , 24 ].…”

Section: Introductionmentioning

confidence: 99%

Optimisation on Thermoforming of Biodegradable Poly (Lactic Acid) (PLA) by Numerical Modelling

Wei

2021

Polymers

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Poly (lactic acid) (PLA) has a broad perspective for manufacturing green thermoplastic products by thermoforming for its biodegradable properties. The mechanical behaviour of PLA has been demonstrated by its strong dependence on temperature and strain rate at biaxial deformation. A nonlinear viscoelastic model by the previous study was employed in a thermoforming process used for food packaging. An optimisation approach was developed by achieving the optimal temperature profile of specimens by defining multiple heating zones based on numerical modelling with finite element analysis (FEA). The forming process of a PLA product was illustrated by modelling results on shape evolution and biaxial strain history. The optimal temperature profile was suggested in scalloped zones to achieve more even thickness distribution. The sensitivity of the optimal results was addressed by checking the robustness under perturbation.

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Computer simulation of thermoforming process and its verification using a rapid tooling mould

Cited by 7 publications

References 3 publications

Thermostamping Simulation of a Carbon Fiber-Reinforced PAEK Composite Stringer

Thermostamping Simulation of a Carbon Fiber-Reinforced PAEK Composite Stringer

Improving the thickness distribution of parts with hybrid thermoforming

Optimisation on Thermoforming of Biodegradable Poly (Lactic Acid) (PLA) by Numerical Modelling

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