Abstract
This work presents a systematic procedure for the detailed, mesoscopic Finite Element simulation of 3D filament wound fiber skeletons with thermoplastic impregnation. First, relevant structural constituents of thermoplastic fiber skeletons are identified and mechanically characterized by means of specially adapted test methods and specimens. In the next step, the mechanical behavior of the structural constituents is simulated in separate FE models, so-called sub-models. This includes the selection, implementation and parametrization of suitable material models. After that, a Finite Element model for a simple demonstrator fiber skeleton is created, the so-called main model, into which the sub-models are integrated. Finally, the simulation results of the main model are compared to mechanical tests of the demonstrator fiber skeleton. The main model developed in this work allows a precise calculation of the maximum bearable load and a good representation of the delamination process occurring before rupture.
Highlights
A promising perspective to open up further lightweight potential in structural components is the use of polymer materials with local continuous fiber reinforcements
The use of modern robot‐based 3D filament winding processes combined with flexible continuous yarns, as practiced in context of the 3D Skeleton Winding technology (3DSW), enables more flexible fiber positioning and extends the range of applications for structural plastic components with local continuous fiber reinforcement. 3D filament winding processes are used to manufacture topology optimized composite structures, so‐called fiber skeletons, by winding a thermoplastic or thermoset impregnated continuous yarn onto a winding tool
The Material Property Degradation feature (MPDG) implemented in ANSYS Mechanical is used to consider the impairment of the material properties which is caused by damage initiation
Summary
A promising perspective to open up further lightweight potential in structural components is the use of polymer materials with local continuous fiber reinforcements. Discrete FE models, in which ribs are represented by rod or beam elements and fiber deflection points are modeled as rigid connections between these elements, are still frequently used for the mechanical evaluation of large filament wound lattices [3,4] This kind of model is not sufficiently precise to consider failure mechanisms within wound reinforcement structures whose failure is typically initiated by stress peaks in complex winding patterns at the fiber deflection points [1,5]. The main model is validated by means of mechanical tests performed on the manufactured demonstrator skeleton It represents a basic FE model for the mechanical analysis of thermoplastic impregnated fiber skeletons which is extensible to arbitrary geometries.
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