Abstract
Detailed knowledge of the local fiber orientation and the local fiber volume content within composite parts provides an opportunity to predict the structural behavior more reliably. Utilizing forming simulation methods of dry or pre-impregnated fabrics allows for predicting the local fiber orientation. Additionally, during the forming process, so-called draping effects like waviness, gapping or shear-induced transverse compression change the local fiber volume content. To reproduce and investigate such draping effects, different manufacturing tools have been developed in this work. The tools are used to create fabric samples with pre-defined deformation states, representing the different draping effects. The samples are evaluated regarding the resulting fiber volume content. The experimental results are compared with the predictions of an analytical solution and of a numerical solution based on draping simulation results. Furthermore, the interaction of the draping effects at arbitrary strain states is discussed regarding the resulting fiber volume content.
Highlights
The structural performance of continuous fiber-reinforced polymer (CoFRP) parts strongly depends on fiber orientation and fiber volume content (FVC)
For complex geometries, forming of composite parts leads to changes in fiber direction and fiber volume content (FVC)
The results show a very good correlation between the analytical solution, the experimental results and the numerical solution
Summary
The structural performance of continuous fiber-reinforced polymer (CoFRP) parts strongly depends on fiber orientation and fiber volume content (FVC). When preforming the two-dimensional textile fabrics like stitched unidirectional non-crimp fabrics (UD-NCF) onto a three-dimensionally curved tool, deformation of the fabric in the form of shearing, waviness or fiber gapping may occur. These deformations result in a reorientation of the fibers and a deviation from the target FVC. A suitable and reliable draping simulation is needed, which provides local information about present roving waviness, gapping or roving compression due to shear This information can be mapped to the structural simulation by means of continuous virtual process chains (a.k.a. computer-aided engineering (CAE) chains) to consider draping effects [3,4,5]
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