Abstract
Inter-ply friction plays a dominant role in the generation of fiber-path defects (e.g. wrinkling) in the consolidation stage of composites manufacturing. In particular, for most thermoset prepregs, the mixed lubrication regime can be a dominating factor controlling the frictional response over the range of the processing window. This article presents a generic computational modelling approach to describe the mixed lubrication regime by combining an inverse hydrodynamic‐lubrication (IHL) theory and an asperity contact model. A homogenized resin film thickness can be derived from this analysis, rather than postulating it as in earlier conventional models. Thermal effects and fiber bed compliance in the inter-layer contact area as well as the influence of the resin rheology are assessed, finally enabling the model to be verified against inter-ply friction experiments under a wide range of processing conditions. The model has been exemplified on a fabric carbon/epoxy prepreg.
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