Woven carbon fibre prepreg is being increasingly used in high-performance aerospace and automotive applications, primarily because of its superior mechanical properties and formability. A wide range of forming simulation options are available for predicting material deformation during the prepreg forming process, particularly change in fibre orientation. Development of a robust validated simulation model requires comprehensive material characterisation and reliable experimental validation techniques.
This paper presents experimental and numerical methods for studying the fibre orientation in multi-ply woven carbon fibre prepreg forming process, using a double-dome geometry. The numerical study is performed using the commercial forming simulation software PAM-FORM and the material input data are generated from a comprehensive experimental material characterisation. Two experimental validation methods are adopted for fibre shear angle measurement: an optical method for measuring only the surface plies, and a novel CT scan method for measuring both the surface plies and the internal plies. The simulation results are compared against the experimental results in terms of fibre shear angle and the formation of wrinkles to assess the validity of the model
