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Double diaphragm forming simulation for complex composite structures

Chen, S.; McGregor, O.P.L.; Endruweit, A.; Elsmore, M.T.; De Focatiis, D.S.A.; Harper, L.T.; Warrior, N.A.

Authors

S. Chen

O.P.L. McGregor

A. Endruweit

M.T. Elsmore

D.S.A. De Focatiis

L.T. Harper

N.A. Warrior



Abstract

A finite element (FE) model has been developed to simulate the double diaphragm forming (DDF) process, to identify potential defects when forming complex 3D preforms from 2D biaxial non-crimp fabric plies. Three different metrics have been introduced to predict and characterise defects, which include local shear angles to determine ply wrinkling induced by over-shear, compressive strains in the primary fibre directions to determine bundle wrinkling, and tensile stresses in the primary fibre directions to determine fabric bridging. The FE simulation is in good agreement with experiments performed on a demonstrator component. Results indicate that fabric bridging occurs in large-curvature regions, which is the dominant defect in DDF, as wrinkling is generally lower than in matched-tool forming due to relatively low forming pressures (up to 1 bar). The axial tensile stress in fibres has been used as a measure to identify suitable positions and orientations for darts, to alleviate fabric bridging and improve surface conformity, whilst minimising the effect on the mechanical performance of the component.

Journal Article Type Article
Publication Date 2017-04
Journal Composites Part A: Applied Science and Manufacturing
Print ISSN 1359-835X
Electronic ISSN 1359-835X
Publisher Elsevier
Peer Reviewed Peer Reviewed
Volume 95
Pages 346-358
APA6 Citation Chen, S., McGregor, O., Endruweit, A., Elsmore, M., De Focatiis, D., Harper, L., & Warrior, N. (2017). Double diaphragm forming simulation for complex composite structures. Composites Part A: Applied Science and Manufacturing, 95, 346-358. https://doi.org/10.1016/j.compositesa.2017.01.017
DOI https://doi.org/10.1016/j.compositesa.2017.01.017
Keywords Fabrics/textiles; Defect; Finite element analysis (FEA); Forming; Preform
Publisher URL http://www.sciencedirect.com/science/article/pii/S1359835X17300295
Copyright Statement Copyright information regarding this work can be found at the following address: http://creativecommons.org/licenses/by-nc-nd/4.0
Additional Information This article is maintained by: Elsevier; Article Title: Double diaphragm forming simulation for complex composite structures; Journal Title: Composites Part A: Applied Science and Manufacturing; CrossRef DOI link to publisher maintained version: https://doi.org/10.1016/j.compositesa.2017.01.017; Content Type: article; Copyright: © 2017 Elsevier Ltd. All rights reserved.

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Copyright Statement
Copyright information regarding this work can be found at the following address: http://creativecommons.org/licenses/by-nc-nd/4.0





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