Composites forming technologies Edited by A.C.Long woo'ssadmaur'peaypoowy/:dny q paianad Wd tt:Ls:9 I10Z'ZZ ZZI'ZEI '8S[ssauppv dl The Textile Institute CRC CRC Press Boca Raton Boston New York Washington,DC WOODHEAD PUBLISHING LIMITED Cambridge England
Composites forming technologies Edited by A. C. Long Copyrighted Material downloaded from Woodhead Publishing Online Delivered by http://woodhead.metapress.com Hong Kong Polytechnic University (714-57-975) Hong Kong Polytechnic University (714-57-975) Saturday, January 22, 2011 6:57:44 PM IP Address: 158.132.122.4
Contents Contributor contact details xi Introduction 1 Composite forming mechanisms and materials 826-75110 characterisation 1 A C LONG and M J CLIFFORD,University of Nottingham, woo'ssaidmaur'peaypoow/:dny Aq paianad UK Wd t:Ls:9 I10Z'Z 1.1 Introduction 1 1.2 Intra-ply shear 3 Axial loading 9 Ply/tool and ply/ply friction 10 .5 Ply bending 12 16 Compaction/consolidation 14 1 Discussion 19 References 2 Constitute modelling for composite forming 22 R AKKERMAN and E A D LAMERS,University of Twente, The Netherlands 2.1 Introduction 2.2 Review on constitutive modelling for composite forming 2.3 Continuum based laminate modelling 2.4 Multilayer effects 2.5 Parameter characterisation 222945 2.6 Future trends 2.7 References 44
Contributor contact details xi Introduction xv 1 Composite forming mechanisms and materials characterisation 1 ACLONG and M J CLIFFORD , University of Nottingham, UK 1.1 Introduction 1 1.2 Intra-ply shear 3 1.3 Axial loading 9 1.4 Ply/tool and ply/ply friction 10 1.5 Ply bending 12 1.6 Compaction/consolidation 14 1.7 Discussion 19 1.8 References 19 2 Constitute modelling for composite forming 22 R AKKERMAN and E A D LAMERS , University of Twente, The Netherlands 2.1 Introduction 22 2.2 Review on constitutive modelling for composite forming 22 2.3 Continuum based laminate modelling 29 2.4 Multilayer effects 34 2.5 Parameter characterisation 35 2.6 Future trends 43 2.7 References 44 Contents Copyrighted Material downloaded from Woodhead Publishing Online Delivered by http://woodhead.metapress.com Hong Kong Polytechnic University (714-57-975) Hong Kong Polytechnic University (714-57-975) Saturday, January 22, 2011 6:57:44 PM IP Address: 158.132.122.4
vi Contents 3 Finite element analysis of composite forming 46 P BOISSE,INSA de Lyon,France 3.1 Introduction:finite element analyses of composite forming, why and where? 46 3.2 The multiscale nature of composite materials and different approaches for composite forming simulations 48 3.3 The continuous approach for composite forming process analysis 50 3.4 Discrete or mesoscopic approach 57 3.5 Semi-discrete approach 59 3.6 Multi-ply forming and re-consolidation simulations 70 3.7 Conclusions 75 3.8 References 75 4 Virtual testing for material formability 80 Sunysijqnd S V LOMOV,Katholieke Universiteit Leuven,Belgium 4.1 Introduction 80 4.2 Mechanical model of the internal geometry of the relaxed state 82 wos' of a woven fabric 4.3 Model of compression of woven fabric 84 4.4 Model of uniaxial and biaxial tension of woven fabric 89 'ssaudmau'peaypoow/: 4.5 Model of shear of woven fabric 93 4.6 Parametric description of fabric behaviour under simultaneous shear and tension 96 02. 到 4.7 Conclusions:creating input data for forming simulations 111 4.8 References 112 5 Optimization of composites forming 117 W-R YU,Seoul National University,Korea 5.1 Introduction 117 5.2 General aspects of optimization 118 5.3 Optimization of composite forming 126 5.4 Conclusions 142 5.5 References 142 6 Simulation of compression moulding to form composites 144 E SCHMA CHTEN BERG,Universitat Erlangen-Nurnberg, Germany and K SK RODOLIES,Institut fur Kunststoffverarbeitung, Germany 6.1 Introduction 144 6.2 Theoretical description of the simulation 145
3 Finite element analysis of composite forming 46 P BO I S S E , INSA de Lyon, France 3.1 Introduction: finite element analyses of composite forming, why and where? 46 3.2 The multiscale nature of composite materials and different approaches for composite forming simulations 48 3.3 The continuous approach for composite forming process analysis 50 3.4 Discrete or mesoscopic approach 57 3.5 Semi-discrete approach 59 3.6 Multi-ply forming and re-consolidation simulations 70 3.7 Conclusions 75 3.8 References 75 4 Virtual testing for material formability 80 S V LO M O V , Katholieke Universiteit Leuven, Belgium 4.1 Introduction 80 4.2 Mechanical model of the internal geometry of the relaxed state of a woven fabric 82 4.3 Model of compression of woven fabric 84 4.4 Model of uniaxial and biaxial tension of woven fabric 89 4.5 Model of shear of woven fabric 93 4.6 Parametric description of fabric behaviour under simultaneous shear and tension 96 4.7 Conclusions: creating input data for forming simulations 111 4.8 References 112 5 Optimization of composites forming 117 W-R YU , Seoul National University, Korea 5.1 Introduction 117 5.2 General aspects of optimization 118 5.3 Optimization of composite forming 126 5.4 Conclusions 142 5.5 References 142 6 Simulation of compression moulding to form composites 144 E SC H M A C H T E N B E R G , UniversitaÈt Erlangen-NuÈrnberg, Germany and K SK R O D O L I E S , Institut fuÈr Kunststoffverarbeitung, Germany 6.1 Introduction 144 6.2 Theoretical description of the simulation 145 vi Contents Copyrighted Material downloaded from Woodhead Publishing Online Delivered by http://woodhead.metapress.com Hong Kong Polytechnic University (714-57-975) Hong Kong Polytechnic University (714-57-975) Saturday, January 22, 2011 6:57:44 PM IP Address: 158.132.122.4
Contents vii 6.3 Examples of use of the simulation 161 6.4 Measurement of the material data 172 6.5 References 174 6.6 Symbols 175 7 Understanding composite distortion during processing 177 M R WIS NOM and K D POTTER,University of Bristol,UK 7.1 Introduction 177 7.2 Fundamental mechanisms causing residual stresses and distortion 177 7.3 Distortion in flat parts 181 7.4 Spring-in of curved parts 186 7.5 Distortion in more complex parts 192 Suysijqnd peaupoo M 7.6 Conclusions 194 7.7 References 195 8 Forming technology for composite/metal hybrids 197 J SINKE,Technical University Delft,The Netherlands woo'ssaudmaur'peaqpoowy/dg 1876-5 8.1 Introduction 197 12.9102. 8.2 Development of composite/metal hybrids 198 8.3 Properties of fibre metal laminates 201 Production processes for fibre metal laminates 205 8.5 Modelling of FML 213 8.6 Conclusions 218 8.7 References 219 9 Forming self-reinforced polymer materials 220 I M WARD and P J HINE,University of Leeds,UK and D E RILEY,Propex Fabrics,Germany 9.1 Introduction 220 9.2 The hot compaction process 220 9.3 Commercial exploitation 224 9.4 Postforming studies 225 9.5 Key examples of commercial products 232 9.6 Future developments 235 9.7 Acknowledgements 236 9.8 References 236
6.3 Examples of use of the simulation 161 6.4 Measurement of the material data 172 6.5 References 174 6.6 Symbols 175 7 Understanding composite distortion during processing 177 M R WI S N O M and K D PO T T E R , University of Bristol, UK 7.1 Introduction 177 7.2 Fundamental mechanisms causing residual stresses and distortion 177 7.3 Distortion in flat parts 181 7.4 Spring-in of curved parts 186 7.5 Distortion in more complex parts 192 7.6 Conclusions 194 7.7 References 195 8 Forming technology for composite/metal hybrids 197 J SI N K E , Technical University Delft, The Netherlands 8.1 Introduction 197 8.2 Development of composite/metal hybrids 198 8.3 Properties of fibre metal laminates 201 8.4 Production processes for fibre metal laminates 205 8.5 Modelling of FML 213 8.6 Conclusions 218 8.7 References 219 9 Forming self-reinforced polymer materials 220 I M WA R D and P J HI N E , University of Leeds, UK and D E RI L E Y , Propex Fabrics, Germany 9.1 Introduction 220 9.2 The hot compaction process 220 9.3 Commercial exploitation 224 9.4 Postforming studies 225 9.5 Key examples of commercial products 232 9.6 Future developments 235 9.7 Acknowledgements 236 9.8 References 236 Contents vii Copyrighted Material downloaded from Woodhead Publishing Online Delivered by http://woodhead.metapress.com Hong Kong Polytechnic University (714-57-975) Hong Kong Polytechnic University (714-57-975) Saturday, January 22, 2011 6:57:44 PM IP Address: 158.132.122.4
viⅷ Contents 10 Forming technology for thermoset composites 239 R PATON,Cooperative Research Centre for Advanced Composite Structures Ltd,Australia 10.1 Introduction 239 10.2 Practicalities of forming thermoset prepeg stacks 240 10.3 Deformation mechanisms in woven fabric prepeg 241 10.4 Tape prepreg 247 10.5 Forming processes 248 10.6 Tooling equipment 250 10.7 Diaphagm forming tooling 251 10.8 Potential problems 252 10.9 Process capabilities 253 10.10 Future trends 253 10.11 References 254 Sunysijqnd 11 Forming technology for thermoplastic composites 256 R BROOKS,University of Nottingham,UK 1876-55 11.1 Introduction 256 11.2 Thermoplastic composite materials(TPCs)for forming 256 woo'ssaudmaur'peaypoowy/:dy 11.3 Basic principles of TPC forming technologies 262 11.4 Forming methods 264 11.5 Some recent developments 273 11.6 Conclusions 275 11.7 References 275 12 The use of draping simulation in composite design 277 J W KLINTWORTH,MSC Software Ltd,UK and A C LONG,University of Nottingham,UK 12.1 Introduction 277 12.2 Zone and ply descriptions 277 12.3 Composites development process 278 12.4 Composites data exchange 281 12.5 Draping and forming simulation 282 12.6 Linking forming simulation to component design analysis 284 12.7 Conclusions 291 12.8 References 292
10 Forming technology for thermoset composites 239 R PA T O N , Cooperative Research Centre for Advanced Composite Structures Ltd, Australia 10.1 Introduction 239 10.2 Practicalities of forming thermoset prepeg stacks 240 10.3 Deformation mechanisms in woven fabric prepeg 241 10.4 Tape prepreg 247 10.5 Forming processes 248 10.6 Tooling equipment 250 10.7 Diaphagm forming tooling 251 10.8 Potential problems 252 10.9 Process capabilities 253 10.10 Future trends 253 10.11 References 254 11 Forming technology for thermoplastic composites 256 R BR O O K S , University of Nottingham, UK 11.1 Introduction 256 11.2 Thermoplastic composite materials (TPCs) for forming 256 11.3 Basic principles of TPC forming technologies 262 11.4 Forming methods 264 11.5 Some recent developments 273 11.6 Conclusions 275 11.7 References 275 12 The use of draping simulation in composite design 277 J W KL I N T W O R T H , MSC Software Ltd, UK and A C LO N G , University of Nottingham, UK 12.1 Introduction 277 12.2 Zone and ply descriptions 277 12.3 Composites development process 278 12.4 Composites data exchange 281 12.5 Draping and forming simulation 282 12.6 Linking forming simulation to component design analysis 284 12.7 Conclusions 291 12.8 References 292 viii Contents Copyrighted Material downloaded from Woodhead Publishing Online Delivered by http://woodhead.metapress.com Hong Kong Polytechnic University (714-57-975) Hong Kong Polytechnic University (714-57-975) Saturday, January 22, 2011 6:57:44 PM IP Address: 158.132.122.4
Contents iX 13 Benchmarking of composite forming modelling techniques 293 J L GORCZYCA-COLE and J CHEN,University of Massachusetts Lowell,USA and J CAO,Northwestern University,USA 13.1 Introduction 293 13.2 Forming process and fabric properties 295 13.3 Experimental 297 13.4 Numerical analyses 313 13.5 Conclusions and future trends 315 13.6 Acknowledgements 316 13.7 References and further reading 317 Index 318 Krnuef'Kepimes
13 Benchmarking of composite forming modelling techniques 293 J L GO R C Z Y C A -CO L E and J CH E N , University of Massachusetts Lowell, USA and J CA O , Northwestern University, USA 13.1 Introduction 293 13.2 Forming process and fabric properties 295 13.3 Experimental 297 13.4 Numerical analyses 313 13.5 Conclusions and future trends 315 13.6 Acknowledgements 316 13.7 References and further reading 317 Index 318 Contents ix Copyrighted Material downloaded from Woodhead Publishing Online Delivered by http://woodhead.metapress.com Hong Kong Polytechnic University (714-57-975) Hong Kong Polytechnic University (714-57-975) Saturday, January 22, 2011 6:57:44 PM IP Address: 158.132.122.4
Contributor contact details (*main contact) 7500AE Enschede The Netherlands Editor E-mail:r.akkerman@ctw.utwente.nl A.C.Long School of Mechanical Materials and Manufacturing Engineering Chapter 3 P.Boisse poo M University of Nottingham Laboratoire de Mecanique des University Park Contacts et des Solides Nottingham NG7 2RD UMR CNRS 5514 UK INSA de Lyon E-mail: France Andrew.Long@nottingham.ac.uk E-mail: Chapter 1 Philippe.Boisse@insa-lyon.fr A.C.Long*and M.J.Clifford Chapter 4 niversi的of No School of Mechanical Materials and S.Lomov Manufacturing Engineering Department of Metallurgy and University Park Materials Engineering Nottingham NG7 2RD Kasteelpark Arenberg 44 UK BE-3001 Heverlee Belgium E-mail: E-mail: mike.clifford@nottingham.ac.uk stepan.lomov@mtm.kuleuven.be Chapter 2 R.Akkerman*and E.A.D.Lamers Chapter 5 W.-R.Yu Construerende Technische Wetenschappen Dept.of Materials Science and Universiteit Twente-CTW Engineering College of Engineering Postbus 217
(* = main contact) Editor A.C. Long School of Mechanical Materials and Manufacturing Engineering University of Nottingham University Park Nottingham NG7 2RD UK E-mail: Andrew.Long@nottingham.ac.uk Chapter 1 A.C. Long* and M.J. Clifford School of Mechanical Materials and Manufacturing Engineering University of Nottingham University Park Nottingham NG7 2RD UK E-mail: mike.clifford@nottingham.ac.uk Chapter 2 R. Akkerman* and E.A.D. Lamers Construerende Technische Wetenschappen Universiteit Twente ± CTW Postbus 217 7500AE Enschede The Netherlands E-mail: r.akkerman@ctw.utwente.nl Chapter 3 P. Boisse Laboratoire de MeÂcanique des Contacts et des Solides UMR CNRS 5514 INSA de Lyon France E-mail: Philippe.Boisse@insa-lyon.fr Chapter 4 S. Lomov Department of Metallurgy and Materials Engineering Kasteelpark Arenberg 44 BE-3001 Heverlee Belgium E-mail: stepan.lomov@mtm.kuleuven.be Chapter 5 W.-R. Yu Dept. of Materials Science and Engineering College of Engineering Contributor contact details Copyrighted Material downloaded from Woodhead Publishing Online Delivered by http://woodhead.metapress.com Hong Kong Polytechnic University (714-57-975) Hong Kong Polytechnic University (714-57-975) Saturday, January 22, 2011 6:57:44 PM IP Address: 158.132.122.4
xii Contributor contact details Seoul National University Aerospace Materials and San 56-1 Silim dong Manufacturing Gwanak-gu Kluyverweg 1 Seoul 151-744 2629HS,Delft Korea The Netherlands E-mail:woongryu@snu.ac.kr E-mail:j.sinke@tudelft.nl Chapter 6 Chapter 9 E.Schmachtenberg I.M.Ward*,P.J.Hine and Universitat Erlangen-Nurnberg D.E.Riley Lehrstuhl fur Kunststofftechnik IRC in Polymer Science Am Weichselgarten 9 Technology 91058 Erlangen-Tennenlohe School of Physics and Astronomy Germany University of Leeds E-mail:Schmachtenberg@lkt.uni- Leeds LS2 9JT UK erlangen.de E-mail:I.M.Ward@leeds.ac.uk K.Skrodolies p.j.hine@leeds.ac.uk Institute of Plastics Processing at Derek.Riley@propexfabrics.com RWTH Aachen University PontstraBe 49 Chapter 10 52062 Aachen R.Paton Germany Cooperative Research Centre for Advanced Composite Structures E-mail:zentrale@ikv.rwth-aachen.de Ltd 506 Lorimer St,Fishermens Bend Chapter 7 豆 Port Melbourne,3207 P M.R.Wisnom*and K.D.Potter Australia Professor of Aerospace Structures University of Bristol E-mail:r.paton@crc-acs.com.au Advanced Composites Centre for Innovation and Science Chapter 11 Queens Building 0.64 R.Brooks University Walk School of Mechanical Materials and Bristol BS8 1TR Manufacturing Engineering UK University of Nottingham E-mail:M.Wisnom@bristol.ac.uk University Park Nottingham NG7 2RD Chapter 8 UK J.Sinke E-mail: Faculty of Aerospace Engineering richard.brooks@nottingham.ac.uk Technical University Delft
Seoul National University San 56-1 Silim dong Gwanak-gu Seoul 151-744 Korea E-mail: woongryu@snu.ac.kr Chapter 6 E. Schmachtenberg UniversitaÈt Erlangen-NuÈrnberg Lehrstuhl fuÈr Kunststofftechnik Am Weichselgarten 9 91058 Erlangen-Tennenlohe Germany E-mail: Schmachtenberg@lkt.unierlangen.de K. Skrodolies Institute of Plastics Processing at RWTH Aachen University Pontstraûe 49 52062 Aachen Germany E-mail: zentrale@ikv.rwth-aachen.de Chapter 7 M. R. Wisnom* and K. D. Potter Professor of Aerospace Structures University of Bristol Advanced Composites Centre for Innovation and Science Queens Building 0.64 University Walk Bristol BS8 1TR UK E-mail: M.Wisnom@bristol.ac.uk Chapter 8 J. Sinke Faculty of Aerospace Engineering Technical University Delft Aerospace Materials and Manufacturing Kluyverweg 1 2629HS, Delft The Netherlands E-mail: j.sinke@tudelft.nl Chapter 9 I.M. Ward*, P.J. Hine and D.E. Riley IRC in Polymer Science & Technology School of Physics and Astronomy University of Leeds Leeds LS2 9JT UK E-mail: I.M.Ward@leeds.ac.uk p.j.hine@leeds.ac.uk Derek.Riley@propexfabrics.com Chapter 10 R. Paton Cooperative Research Centre for Advanced Composite Structures Ltd 506 Lorimer St, Fishermens Bend Port Melbourne, 3207 Australia E-mail: r.paton@crc-acs.com.au Chapter 11 R. Brooks School of Mechanical Materials and Manufacturing Engineering University of Nottingham University Park Nottingham NG7 2RD UK E-mail: richard.brooks@nottingham.ac.uk xii Contributor contact details Copyrighted Material downloaded from Woodhead Publishing Online Delivered by http://woodhead.metapress.com Hong Kong Polytechnic University (714-57-975) Hong Kong Polytechnic University (714-57-975) Saturday, January 22, 2011 6:57:44 PM IP Address: 158.132.122.4
Contributor contact details xiii Chapter 12 Chapter 13 J.W.Klintworth*and A.C.Long J.L.Gorczyca-Cole and J.Chen* MSC Software Ltd University of Massachusetts Lowell MSC House One University Avenue Lyon Way Lowell,MA 01854 Frimley USA Camberley E-mail:Julie chen@uml.edu Surrey GU16 7ER UK J.Cao E-mail: Department of Mechanical john.klintworth@mscsoftware.com Engineering Northwestern University 2145 Sheridan Road Evanston,IL 60208-3111 USA E-mail:jcao@northwestern.edu wo'ssaudmau'peaypoowy/:dng Aq paanad
Chapter 12 J.W. Klintworth* and A.C. Long MSC Software Ltd MSC House Lyon Way Frimley Camberley Surrey GU16 7ER UK E-mail: john.klintworth@mscsoftware.com Chapter 13 J.L. Gorczyca-Cole and J. Chen* University of Massachusetts Lowell One University Avenue Lowell, MA 01854 USA E-mail: Julie_chen@uml.edu J. Cao Department of Mechanical Engineering Northwestern University 2145 Sheridan Road Evanston, IL 60208-3111 USA E-mail: jcao@northwestern.edu Contributor contact details xiii Copyrighted Material downloaded from Woodhead Publishing Online Delivered by http://woodhead.metapress.com Hong Kong Polytechnic University (714-57-975) Hong Kong Polytechnic University (714-57-975) Saturday, January 22, 2011 6:57:44 PM IP Address: 158.132.122.4
Introduction Composite materials are available in many forms and are produced using a variety of manufacturing methods.A range of fibre types is used-primarily carbon and glass -and these can be combined with a variety of polymer matrices.This book concentrates on 'long'fibre composites,including fibres from a few centimetres in length(i.e.excluding injection moulding compounds). So the processing methods of interest include compression moulding of poo M thermoplastic or thermoset moulding compounds;resin transfer moulding based on dry fibre preforms;forming and consolidation of thermoset prepreg and thermoplastic sheets;and forming of new material forms including composite/ 759 metal laminates and polymer/polymer(self-reinforced)composites. Whatever the material form or manufacturing process,there is one common step:forming of initially planar material into a three dimensional shape.This is the focus ofComposite Forming Technologies'The book includes descriptions of industrial forming processes,case studies and applications,and methods used 四 to simulate composite forming.This description is intended for manufacturers of polymer composite components,end-users and designers,researchers in the fields of structural materials and manufacturing,and materials suppliers.Whilst the bulk of the text is devoted to modelling tools,the intention is to provide useful guidance and to inform the reader of the current status and limitations of both research and commercial tools.It is hoped that this will form essential reading for the users of such modelling tools,whilst encouraging others to'take the plunge'and adopt a simulation approach to manufacturing process design. This text may be considered broadly in two halves,with Chapters 1-7 covering the fundamental aspects of modelling and simulation,and Chapters 8- 13 describing practical aspects including manufacturing technologies and modern practices in composites design.The first chapter provides a comprehensive introduction to the range of deformation mechanisms that can occur during forming for a range of materials,along with appropriate test methods and representative data.Chapter 2 describes fundamental constitutive models as required for composite forming,including the bases for commercial kinematic (draping)and mechanical (forming)simulations.The latter topic is
Composite materials are available in many forms and are produced using a variety of manufacturing methods. A range of fibre types is used ± primarily carbon and glass ± and these can be combined with a variety of polymer matrices. This book concentrates on `long' fibre composites, including fibres from a few centimetres in length (i.e. excluding injection moulding compounds). So the processing methods of interest include compression moulding of thermoplastic or thermoset moulding compounds; resin transfer moulding based on dry fibre preforms; forming and consolidation of thermoset prepreg and thermoplastic sheets; and forming of new material forms including composite/ metal laminates and polymer/polymer (self-reinforced) composites. Whatever the material form or manufacturing process, there is one common step: forming of initially planar material into a three dimensional shape. This is the focus of `Composite Forming Technologies'. The book includes descriptions of industrial forming processes, case studies and applications, and methods used to simulate composite forming. This description is intended for manufacturers of polymer composite components, end-users and designers, researchers in the fields of structural materials and manufacturing, and materials suppliers. Whilst the bulk of the text is devoted to modelling tools, the intention is to provide useful guidance and to inform the reader of the current status and limitations of both research and commercial tools. It is hoped that this will form essential reading for the users of such modelling tools, whilst encouraging others to `take the plunge' and adopt a simulation approach to manufacturing process design. This text may be considered broadly in two halves, with Chapters 1±7 covering the fundamental aspects of modelling and simulation, and Chapters 8± 13 describing practical aspects including manufacturing technologies and modern practices in composites design. The first chapter provides a comprehensive introduction to the range of deformation mechanisms that can occur during forming for a range of materials, along with appropriate test methods and representative data. Chapter 2 describes fundamental constitutive models as required for composite forming, including the bases for commercial kinematic (draping) and mechanical (forming) simulations. The latter topic is Introduction Copyrighted Material downloaded from Woodhead Publishing Online Delivered by http://woodhead.metapress.com Hong Kong Polytechnic University (714-57-975) Hong Kong Polytechnic University (714-57-975) Saturday, January 22, 2011 6:57:44 PM IP Address: 158.132.122.4