Thermo-hydroforming of a fiber-reinforced thermoplastic composites considering fiber orientations

Abstract

The Thermoplastic woven composites were formed using a composite thermal hydroforming process, utilizing heated and pressurized fluid, similar to sheet metal forming. This study focuses on the modification of 300-ton pressure formation and predicts its behavior. Spectra Shield SR-3136 is used in this study and material properties are measured by experiments. The behavior of fiber-reinforced thermoplastic polymer composites (FRTP) was modeled using the Preferred Fiber Orientation (PFO) model and validated by comparing numerical analysis with experimental results. The thermo-hydroforming process has shown good results in the ability to form deep drawn parts with reduced wrinkles. Numerical analysis was performed using the PFO model and implemented as commercial finite element software ABAQUS / Explicit. The user subroutine (VUMAT) was used for the material properties of the thermoplastic composite layer. This model is suitable for working with multiple layers of composite laminates. Model parameters have been updated to work with cohesive zone model to calculate the interfacial properties between each composite layer. The results of the numerical modeling showed a good correlation with the molding experiment on the forming shape. Numerical results were also compared with experimental results on punch force-displacement curves for deformed geometry and forming processes of the composite layer. Overall, the shape of the deformed FRTP, including the distribution of wrinkles, was accurately predicted as shown in this study.