Validation of a Simulation Methodology for Thermoplastic and Thermosetting Composite Materials Considering the Effect of Forming Process on the Structural Performance.

Lorenzo Sisca,Christian Liebold,Patrizio Tiziano Locatelli Quacchia,Salvatore Scalera,Alberto Festa,Alessandro Messana,Marta Palenzona,Massimiliana Carello,Andrea Giancarlo Airale,Marco Monti,Paolo Codrino,Alessandro Ferraris,Andrea Romeo

doi:10.3390/polym12122801

Lorenzo Sisca, Christian Liebold + Show 11 more

Open Access

https://doi.org/10.3390/polym12122801

Copy DOI

Abstract

This research work investigated the influence of the press molding manufacturing process on the mechanical properties, both for thermoplastic and thermosetting fiber reinforced composite materials. The particular geometry of the case study, called Double Dome, was considered in order to verify the behavior of the Thermoplastic and Thermosetting prepreg in terms of shell thickness variation and fibers shear angle evolution during the thermoforming process. The thermoforming simulation was performed using LS-DYNA® Finite Element Analysis (FEA) code, and the results were transferred by Envyo®, a dedicated mapping tool, into a LS-DYNA® virtual model for the structural simulation. A series of Double Dome specimens was produced with industrial equipment, and a bending experimental test was been carried on. Finally, a numerical-experimental correlation was performed, highlighting a significant forecast of the mechanical properties for the considered component.

Highlights

In recent years, the world is going through a period of radical change driven by greater attention to environmental impact of human activities
The aim of this paper was to investigate on glass and carbon organosheets andmechanical carbon epoxy properties of the material, in particular, the shear properties of fabric, that were characterized by Lee composites the influence of the thermoforming process on the final mechanical properties for the case et al (2008) [16], and the tool-ply friction behavior, that was studied by Fetfatsidis et al (2013) [17]
The aim of this paper was to investigate on glass and carbon organosheets and carbon epoxy studycomposites called Procomp, but it of did allow an in-depth the fiber shear deformation the influence thenot thermoforming processevaluation on the finalof mechanical properties for the case

Summary

Introduction

The world is going through a period of radical change driven by greater attention to environmental impact of human activities. In the automotive field, new mobility paradigms and innovative vehicle construction and powertrain are needed to cope with this global issue. Lightweight vehicles focalize a particular attention because of the direct effect on the fuel consumption: Sinha and Tyagi (2019) indicate that a 50% increase in vehicle mass results in an increase of approximately 60% in fuel consumption [1], and Mayyas et al (2012) assert that a 10% reduction in vehicle weight translates to a 5% increase in miles per gallon [2]. A promising strategy to reduce the vehicle mass is the use of innovative lightweight materials, like polymer composite materials. Brooks et al (2000) report that Volkswagen realized a front-end panel for Golf with Glass. Al-Qureshi (2001) tested a leaf spring made in glass fiber reinforced plastic [4]

Objectives

Methods

Discussion

Conclusion