Numerical modeling of a hybrid forming process for three-dimensionally curved fiber-metal laminates

Werner, Henrik O.; Dörr, Dominik; Henning, Frank; Kärger, Luise

doi:10.1063/1.5112524

Cited by 14 publications

(11 citation statements)

References 11 publications

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“…Hand lay-up Low cost of tooling [364,365] The process is simple [364] Large, complex parts can be formed [365] Flexible design [364] Production technology is easy to master [365] Any combination of fibres and matrix materials can be used [364] The process is time-consuming [364] Powder and bad smells are involved in the production environment [365] Quality of the final product depends on highly skilled manpower [364] The process is labour intensive [366] Spray lay-up Suitable for small-to medium-volume parts [364] Low-cost tooling [364] It is difficult to control the fibre volume fraction [364] There is difficulty in removing trapped air from the moulding [365] The process does not provide a good surface finish [364] RTM Complex parts can be fabricated [307,309,366] Higher volume outputs and much lower cycle times than other methods [308,366] Production of smooth-surfaced parts on both inner and outer surfaces of the mould [307,308,366]. Components can be produced up to 5-20 times faster compared with open moulding techniques [367] High production volumes require offset high tooling costs [307,308,367] Difficult to effectively improve the fibre volume content of the product [367] The size of the part is limited by the mould [308,367].…”

Section: Methods Advantage Disadvantagementioning

confidence: 99%

“…As a result, the air stream "imposes" the fibres and the resin on th mould surface [17,305,306]. RTM is a method of manufacturing laminates in closed forms, which consists o forcing catalysed resin into a tightly closed mould, previously filled with reinforcing fi bres and/or sandwich material [307][308][309]. The counter-mould is made similarly to th main mould.…”

Section: Lay-up Techniquementioning

confidence: 99%

“…The RTM/LRTM method allows the share of re inforcement in the total mass of the composite (over 60%) to be increased compared to for example, hand lay-up lamination [317]. RTM and LRTM technologies are mainly used RTM is a method of manufacturing laminates in closed forms, which consists of forcing catalysed resin into a tightly closed mould, previously filled with reinforcing fibres and/or sandwich material [307][308][309]. The counter-mould is made similarly to the main mould.…”

Section: Lay-up Techniquementioning

confidence: 99%

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New Advances and Future Possibilities in Forming Technology of Hybrid Metal–Polymer Composites Used in Aerospace Applications

et al. 2021

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Fibre metal laminates, hybrid composite materials built up from interlaced layers of thin metals and fibre reinforced adhesives, are future-proof materials used in the production of passenger aircraft, yachts, sailplanes, racing cars, and sports equipment. The most commercially available fibre–metal laminates are carbon reinforced aluminium laminates, aramid reinforced aluminium laminates, and glass reinforced aluminium laminates. This review emphasises the developing technologies for forming hybrid metal–polymer composites (HMPC). New advances and future possibilities in the forming technology for this group of materials is discussed. A brief classification of the currently available types of FMLs and details of their methods of fabrication are also presented. Particular emphasis was placed on the methods of shaping FMLs using plastic working techniques, i.e., incremental sheet forming, shot peening forming, press brake bending, electro-magnetic forming, hydroforming, and stamping. Current progress and the future directions of research on HMPCs are summarised and presented.

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Section: Methods Advantage Disadvantagementioning

confidence: 99%

Section: Lay-up Techniquementioning

confidence: 99%

Section: Lay-up Techniquementioning

confidence: 99%

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New Advances and Future Possibilities in Forming Technology of Hybrid Metal–Polymer Composites Used in Aerospace Applications

et al. 2021

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“…This is important in de ning the resin ow pattern during textile composite fabrication processes that use mold pressure. 1 2 Using the 3-D nite-element process, the complex 3D stitched fabric geometry and the spatially different yarn properties can be modelled [23,5]. The development of suitable material models and a geometry description can, however, be tremendous challenges and no published studies on this subject are currently available.…”

Section: Introductionmentioning

confidence: 99%

Formability Characterization of Stitched Preform Toward Applying for Composite Structures

Saboktakin

2022

Preprint

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Characterization of the stitched textile preform is required for the prediction of textile preforms forming in the fabrication of composite structures for aerospace applications. The behavior of the preform in compression during resin injection into the preform is one of the critical issues in achieving a high-quality composite for space structures. This paper concentrates on the experimental and finite element analysis of compaction for textile preform. The investigation of mechanical properties of preforms during compression tests revealed that formability parameters of a preform can be altered by the stitching process. The load-deformation response, which is depicted in detail, had the greatest influence on the preform deformation. Compression of the stitched preform resulted in less tow undulation in the plane direction and more stitching thread undulation in the thickness direction, while the stitching thread stimulated the preform to endure more pressure. The results provided more detailed insights into the effects of compaction on other properties such as permeability and composite mechanical behavior, which is based on the internal geometry of 3D textile preforms.

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“…1). In previous work, the authors presented a finite element (FE) model and a parametric study to simulate this process [3,4]. They have shown that the common known compressive stresses in deep drawing processes require an in-plane compression sensitive membrane modelling of the fabric.…”

Section: Intr Introduction Oductionmentioning

confidence: 99%

Material Modelling of Fabric Deformation in Forming Simulation of Fiber-Metal Laminates – A Review on Modelling Fabric Coupling Mechanisms

Werner¹,

Schäfer²,

Henning³

et al. 2021

Esaform 2021

Self Cite

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During forming of complex fiber-metal laminates (FML), compressive stress zones occur. In pure textile forming, these compressive stresses typically lead to extensive wrinkling. In FML forming, however, wrinkling is partly hindered by the metal layers. Thus, combined stress states occur, where compression influences the deformation. In forming simulation, these compressive stresses can lead to erroneous formation of shear bands within the fabric layer, if the deformation behavior is not modelled correctly. Simple fabric models neither consider interactions between roving directions nor model interactions between membrane strains and shear strains. More advanced invariant-based hyperelastic material models are able to capture these interactions, but only consider tension and shear, while disregarding compression. A common assumption is to set the fabric compression stiffness close to zero. Experimentally, the in-plane fabric compression stiffness has not been determined so far. However, in FML forming, the compression stiffness and the combined compression-tension-shear behavior becomes relevant. In this article, the authors summarize and analyze the capacity of state-of-the-art fabric material models to predict the deformation behavior of fabrics under combined loading. Based on these findings, conclusions are drawn for a new macroscopic modeling approach for woven fabrics, including coupling of tension, compression and shear.

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Numerical modeling of a hybrid forming process for three-dimensionally curved fiber-metal laminates

Cited by 14 publications

References 11 publications

New Advances and Future Possibilities in Forming Technology of Hybrid Metal–Polymer Composites Used in Aerospace Applications

New Advances and Future Possibilities in Forming Technology of Hybrid Metal–Polymer Composites Used in Aerospace Applications

Formability Characterization of Stitched Preform Toward Applying for Composite Structures

Material Modelling of Fabric Deformation in Forming Simulation of Fiber-Metal Laminates – A Review on Modelling Fabric Coupling Mechanisms

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