3D modeling of squeeze flow of unidirectionally thermoplastic composite inserts

Abstract

Thermoplastic composites are attractive because they can be recycled and exhibit superior mechanical properties. The ability of thermoplastic resin to melt and solidify allows for fast and cost-effective manufacturing processes, which is a crucial property for high volume production. Thermoplastic composite parts are usually obtained by stacking several prepreg plies to create a laminate with a particular orientation sequence to meet design requirements. During the consolidation and forming process, the thermoplastic laminate is subjected to complex deformation which can include intraply and/or interply shear, ply reorientation and squeeze flow. In the case of unidirectional prepregs, the ply constitutive equation, when elastic effects are neglected, can be modeled as a transversally isotropic fluid, that must satisfy the fiber inextensibility as well as the fluid incompressibility. The high-fidelity solution of the squeeze flow in laminates composed of unidirectional prepregs was addressed in our former works by making use of an in-plane-out-of-plane separated representation allowing a very detailed resolution of the involved fields throughout the laminate thickness. In the present work prepregs plies are supposed of limited dimensions compared to the in-plane dimension of the part and will be named inserts. Again within the Proper Generalized Decomposition framework high-resolution simulation of the squeeze flow occurring during consolidation is addressed within a fully 3D in-plane-out-of-plane separated representation.