Akkerman, R.

Haanappel, S.P.

Rietman, A.D.

Sachs, U.

Akkerman, Remko

Rietman, Bert

Haanappel, Sebastiaan

Sachs, Ulrich

University of Twente Research Information

TowMan R. AkkeThermoP AbstractRobust apreventinmaterial bthe procecharacterDevelopmsimulatioand impr   Keyword  IntroducEngineerprocess. design angeneric pprototypeplanning Fig.1). Hprocess icases. Issto problea later stabut may phases wUsually, more coproblemsare likelyproduct dFig.1 Engiprocess.  Clearly, cost savearly in with the are no ards Dufacturman, B. Rielastic comp nd reliable g major tool ehaviour neess defects toisation methoent of an ens in the detaoving the oves: Virtual Protion ing design isIdeally, cond detailed deroduct devel manufactuand tool maowever, it is not that liues disregardms during dege. This mayalso requireith large imthe further instly the m encountered to have the evelopment cneering design the use of viings by prethe design pinvestments exception toesign ring Utman, S. Haosites Reseprocess simuand product dds to be iden be preventedds for fabric aasily accessibiled design prall cost-effectotyping, Con recognised tceptual desigsign are sequeopment procering (requirnufacturing) s well knownear in timeed in earliertailing the ori be corrected modificationpact on the the developmodifications.  during the plargest negatiosts.  phases in the prtual tools cadicting produrocess. The required. Com this genefor Thesing Panappel, U. arch Centrelations can esign modifitified, modell. The dominnd unidirectile database hase of thermtiveness. stitutive Modo be an iteratn, embodimntial phases oss, followeding productand testing (n that the r in most of phases can lginal solution while detailis in the ear whole desient process, In this senroduction phve impact on roduct developmn result in laction problesavings increposite produral observatirmoprocessSachs & Universitysave significcations in theed and characant deformational reinforceof material poplastic compels, Characteive ent f a  by ion see eal the ead  in ng, lier gn. the se, ase the ent rge ms ase cts on. ThmacoucomcomdevObandmufrieoththewhwilterof  CoPrepotprosolmaproproanddepholprethephaA reqmotheintlastic C Simul of Twente, ant costs dur later producterised correcon mechanismd thermoplasroperty dataosite producrisation, Implermoplastic cchine and tnterparts. Prposites are hpetitive thelopment.  viously, these robust to best be easily andly and muer software t software neeere it is usedl differ from ms of requirethe predictionmposites Forss forming oential of shoduction. As utions for laterials in duction probcess induced tearing. Thendent on ders, blank dictive softwse defects canse, in which successful pruires a suffist relevant rmoplastic lara-ply shear, iompoation Enschede, Ting the detat developmently to generas during fortics are discus will facilitats, reducing thementation omposites tyooling costs ocess simulatence importaermoplastic  virtual tools successful. Tccessible, thest have convools in the deds to match : applicationsthose for detaments, level s. ming Simulaf thermoplastrt cycle timsuch, it is rge scale appa range oflems in this p defects such e occurrencdetails such shape, size are with th be used onlydetails of thisediction of thciently accurphysical pheminates, thenter-ply shearsites he Netherlailed design t phases. Thete useful predming and thesed. te the use ofeir developmpically requithan their ions for thernt, if not esscomposite  must be accuhe required i software muenient interfsign chain. Lwith the des for conceptuiled design puof detail andtions ic compositees required one of the lication of c industries. articular casas warpage, e of these das tool radand  lay-upe purpose to in the detail kind will be ese defects fate descriptionomena. Inse are recog/friction, toonds phase by  essential ictions of  relevant  forming ent times re higher thermoset moplastic ential, for product rate, fast nput data st be user aces with ogically, ign phase al design rposes in  accuracy s has the for mass candidate omposite Typical e concern wrinkling efects is ii, blank . Hence,  prevent ed design defined. irst of all n of the forming nised as l/laminate friction Fig.2). Fig.2 Defcompositesintra-ply sh The reinthese defwill behaplies, andiscontinlaminate appears tstructurecontinuouHaving phenomeappropriabe implemTo be of data whicand reprforming without e Intra-plyThe intrdominateLarge sh(dependinmethods response,extensionFig.3 Pictu Benchmaresponsesquantitatiexperimeand bending ormation mec. From left to rigear, inter-ply slipforcement strormation mecve entirely did in turn veuous fibres. between plieo be strongly. Here, we s fibre plies. established na, these nete constitutivented correcany use, it wh must have oducible mansimulation soasily accessib behaviour a-ply behavd by a trelear angles cang on the are availab e.g. the p test (Fig.3). re frame (left) anrk results [ have consive agreemntal set-ups, (schematicalhanisms in uht: axial intra-p and bending. ucture has ahanisms. Unfferent from ry different Also the is of differen affected by twill restricthe nature ed to be de model. Thistly in the simill then need mbeen determiner. It is veftware will ble material priour of wolis-frame she be imposedfabric constile to measicture frame d bias extension 1] show thastent trends, ent betwat least forly illustratednidirectional fly shear, transv large effect idirectional pfabric reinforfrom plies wnteraction int reinforcemhe reinforcemt ourselves of the relevescribed by  in turn needulation softwaterial propened in a reliary unlikely te widely apploperty data. ven fabrics ar deformati with little eftution). Seveure this sh and the b(right) test. t the measuwith reasonaeen differdry fabrics. in  ibre erse on lies ced ith  a ent ent to ant an s to are. rty ble hat ied is on. fort ral ear ias  red ble ent  In addfib[2]andWhperactpertembeedatUndefno dirtrasentemstaat a carFig(rigspli A r[3]seetracriet.arecthetheangchafuntermoOnit consimneetheition to this,re tensioning. In this case  only very ere most offormed on dual forming formed withperatures. On used in thea is availableidirectional pormation apafibres to resection. Howensverse diresitive to dperature whete. This compforming temppreliminary bon/PEEK (F.4 Result of a picht) on unidirectitting and severe ange of expe, resulting mingly similnsverse behatical evaluatil. [4] propotangular barsrmal stability accurate mele. With tracterise thection of temms of viscoedulus versus ly after havinis possible tostitutive moulations. As ds to take int fibrous reinfthere is expe affects the athere is no stalittle quanti the experimry fabrics at process is  impregnatenly few expese conditions. lies have anrt from in-pltrict extensiover, the lack oction makesamage (tean the matrixlicates characeratures, as ilshear testinig.4).  ture frame test (lonal carbon/PEEstrain localisatiorimental set-uin a wide ar material prviour of unidon of thesesed a tor in a rheom in an inert easurement ohis set-up  intra-ply perature andlastic properfrequency or tg characterise select or ddel to be a minimum, o account theorcement, as trimental evidpparent sheandardised testative data ental work room temperof course d laminates rimental set- and little qu additional ane shear, asn normal to f reinforcem unidirectionring), also  is in a toughterisation exlustrated by ag on unideft) and a bias exK, respectively n.  ps have beenrange of voperties relairectional pl methods, Hsion experimeter, providnvironment, af torque andit was poshear respon deformatioties (storage ime).  d the materiaevelop an apused in thethis constituti anisotropy inhe stiffnessesence that r rigidity t method, available. has been ature, the normally at high ups have antitative mode of there are the fibre ent in the al plies at high  rubbery periments  result of irectional  tension test showing ply  proposed alues for ted to the ies. After aanappel ent on ing good s well as  twisting ssible to se as a n rate in and loss l at hand, propriate forming ve model duced by  of fibres and matrcompositinterpretediscrete single coplastic tyend. Theaddition related reinforceThe framequationsbased on to say, thmicromeextensionobservedAdditionlinear) aequationsproperty  Inter-plyThe motiwith respThis fricresponse counter sevidence pressure perceptiothicknessmatrix asleads to a where  the shearU the reThis descnot depeapproximfriction b where thusually nThe charof thermorequires have beethrough Thije desuited folittle timeix differ mane material d or as a sfractions (e.gntinuum. Elapes of descri resulting conof terms (coto the sepment structurework for  of fibre reicontinuum mis continuumchanics, e.g., buckling an in dry fabal elastic, vnd plastic ef, in generadata.  behaviour on of plies wect to tool sution can bedue to the inurface. Limitthat the fricand sliding vns is that of  h acting as  a viscous f simple formu , ,T p   is the shear s rate, T the telative velocitription woulnd on pressuation can beetween two s∙  e dynamic coot depend on acterization oplastic compa dedicated n reported inand some usveloped a pr routine fric per experimy orders of during forystem comp. fibres and stic, viscous, ptions have bstitutive equnnected in searate constite [5].  continuum tnforced mateechanics argu approach di related to d compactioric deformatisco-elastic fects requirel requiring ith respect torfaces is restr explained teraction of fed experimention depends elocity. Onea resin rich la lubricant. luid (possiblylation for int, with tress,  the rmperature, p y between thd imply that re. Alternativ assumed, moolids, efficient of pressure and f ply-ply andosites at formset-up. Only  literature, soing a pull-ouull-through tion measureent [10]. magnitude. Tming can osed of sevematrix) or aviscoelastic een used to ation will beries or paraluents and ype constitutrials ([6], [7]ments. Needlsregards detaibending, shn of the towsions ([8], [(linear or n more compmore mate each other icted by frictias a compoibres, matrix tal work shoon temperatu of the simpayer of arbitrConsidering  shear thinnier-ply slip, ,Uh  esin viscositythe pressure e two surfacthe friction dely, a Coulore applicablefriction  wosliding veloci tool-ply fricting temperatufew test set-me using a pt principle. Tset-up whichments requirhe be ral s a and this  an lel) the ive ) is ess led ear,  as 9]). on-lex rial and on. site and ws re, lest ary the ng) (1) ,  and es. oes mb  to (2) uld ty. ion res ups ull-en  is ing Exon thapreperbetleasheFigexp ThmaandstrumavelresStras Renotdoenecesshypfibbetob BeVelitecomresbenFigcom A nKEa rh1friction force (N)tensive testingwoven fabrict the dependessure can be spective. Evween the fabds to the samar forces as o.5 Tool/ply frerimental resultsis mesoscopcroscopic res the film cture, the croscopic pocity as inpponse can ibeck relationa function of grettably, this apply to unis not genessary to gentially hydrothesis is onre contact ween lead tserved in expending ry limited erature on theposites in ponse will bding and tran.6 Kirchhoff bendbination with intovel set-up wS set-up for feometer fixtu020040060080°C 20 mm/min180°C 100 mm/min180°C 500 m20() and analysis reinforced thncy of the frexplained froaluating the ric structure ae trends and bserved expeiction forces  vs. model predicic model is ponse (i.e. thethickness) wresin viscosressure, temut. In this be simplified, giving the cthe Hersey nu simple mesodirectional plierate the enerate a rodynamic lube of mixed luand hydrodyo the overalriments.  xperimental  flexural respforming cone somewhere sverse shear ing (left), with iner-ply shear (rigas developedlexural rigidire (Fig.7).  m/min0°C 20 mm/min200°C 100 mm/min200°C 500 mm/220° by ten Thijeermoplasticsiction on velm a meso-mhydrodynamnd the countthe same magrimentally (Fion glass/PP tions [12]. able to pr coefficient oith only thity relation perature andcase the ma subsequenoefficient of mber He = scopic approes. This fibrehydrodynamiesin film lerication. Oubrication, whnamic interal tool-ply frdata is avaonse of therditions. The in between (Fig.6). tra ply shear (mht).  recently, basty and implemminC 20 mm/min220°C 100 mm/min220°C 500 mm/m et al [11] indicated ocity and echanical ic forces er surface nitude of g.5).  laminates: edict the f friction e fabric and the  sliding croscopic tly to a friction  U/p. ach does  structure c forces ading to r current ere fibre-ction in iction as ilable in moplastic laminate Kirchhoff  iddle) and a ed on the ented as inexp (avg)meso modelFig.7 Comp The presmooth dtest methcharacterImplemeAn accurcope wencountecombinatdeformatHere we as preseAniFormintra-ply well as accordanresponsesup and ponecessarycompositas describApplicatThe methand bencexperimepresentedwith variisotropic carbon fresins (FiFig.8 Valid Charactedifferent then inpuosite bending tesliminary reseformations od has largisation of the ntation ate numericaith the ered in thermoion with ions due to temploy a dednted in [13 software. Tresponse, intelaminate bence with th. In parallel,pulating a m input data fe materials, ued. ion and Resuods outlined hmarked agants. An exa in [14]. A sous thermopllay-up of woibres embeddg.8).  ation of composirisation of thsets of matet to the comt set-up within aults show and good repe potential flexural behal solution haxtremely hplastic formithe large he ease of inicated implici] and implehe constitutr-ply and tooding have be experimen TPRC is woaterial databaor the relevasing the charlts above are criinst results omple of thistiffener rib wastic laminatven or unidired in differe tes forming simue different mrial propertyposites form standard rheomethe approprroducibility. Tfor standardiviour. s to be ableigh anisotrong processesnon-orthogotra-ply shearit FE formulatmented in ive models l-ply frictioneen selectedtally obserrking on settse to provide nt thermoplaacterisation totically evaluaf press form validation was press formes with a quectional, glassnt thermoplalations [14]. aterials leads data which ing simulatioter. iate he sed  to py , in nal ng. ion the for , as  in ved ing the stic ols ted ing as ed asi- or stic   to are ns. WrandthewaundCoSimreqcorstaproreqpoof sofexpthecombe effAcTh(TPGeProackRe[1][2][3][4][5][6][7][8][9][10[11[12[13[14inkles were p the predicte experimentas found. Serway to impnclusion ulations of uire the righrect material ble and acgress has beeuired characssibilities to dmaterial proptware fits weected that the detailed posite produreduced, ectiveness.   knowledgeme ThermoplaRC) is suppolderland & Ogramme EFRnowledged.ferences J. Cao, R. A(2008), 1037P. Harrison,Comp.A 43 P. HarrisonDesign andWoodhead,S.P. HaanapAkkerman, PS.W. HsiaoMech. Eng. T.G. RogersA.J.M. SpenS.V. LomovEsaform 200G. Hivet aGlasgow, Un] R.H.W. tenForming 2,  ] R.H.W. ten der Meer, Co] R. AkkermaR.H.W. tenSpain. ] R.H.W. tenComp. Met3141-3150.] S.P. HaanaB. Rietman,506 (2012),redicted in thd strain fieldl data. Qualitaensitivity srove on the qcomposites t constitutiveproperty datacurate numen made in thterisation mevelop an easerty data. Prll in the desse simulationdesign phascts. Product dimproving ents stic Comported by the Rverijssel teamO 2007-201kkerman. P. B-1053. F. Abdiwi, Z. G(2012), 903-91, M.J. Cliffor manufacture 2005. pel, R.H.W. tenroc. Esaform 2, N. Kikuchi, 177 (1999), 1-3, Composites, 2cer, Comp.A, 3, Tz. Stoilova4, Trondheim,nd P. Boisseited Kingdom Thije, R. Asuppl.1 (2010), Thije, R. Akkemp.A 42 (2011n, M.P. UbbiThije, Proc. E Thije, R. Akh. in Appl. Mppel, U. Sac and R. Akkerm237-242.  e correct critis compared tively good atudies are uantitative reforming si models, fed and implemrical scheme recent yearethods, opeily accessibleovided the sign chain, its will find goe of therevelopment the overasite Researcegion Twent, by means o3, which is oisse et al, Cuo, P. Potluri4. d, In A.C. Lof textile c Thije, A.D. R011, Belfast, IComp. Meth4. 0 (1989), 21-21 (2000), 1311 and I. Verp Norway, 345-3, Proc. Esafo, 787-790. kkerman, Int.J197-200.  rman, M. Ubbi), 950-960. nk, M.B. de saform 2007,kerman and Jech. Eng. 19hs, R.H.W. an, Key Eng.cal areas, well with greement currently sults. mulations  with the ented in a e. Good s with the ning the  database imulation  is to be od use in moplastic times can ll cost-h Centre e and the f the GO gratefully omp.A 39 , W.R. Yu, ong (ed), omposites, ietman, R. reland. . in Appl. 7.  -1321. oest, Proc. 48. rm 2006, . of Mat. nk, L. van Rooij and  Zaragosa, . Huétink, 6 (2007), ten Thije,  Mat. 504-

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Towards Design for Thermoplastic Composites Manufacturing Using Process Simulation

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Towards Design for Thermoplastic Composites Manufacturing Using Process Simulation

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