Philippe Boisse

Meso-macro simulation of the woven fabric local deformation in draping

The paper reports results of such combined meso-macro modelling for a plain weave carbon fabric with spread yarns. The boundary conditions for a local meso-model are taken from the macro draping simulation. The fabric geometry is modelled with WiseTex and transferred to the finite element package. A hyperelastic constitutive model for the yarns (Charmetant – Boisse) is used in the meso-modelling; the model parameters are identified and validated in independent tension, shear, compaction and bending tests of the yarn and the fabric. The simulation reproduces local yarn slippage and buckling, for example, the yarn distortion on the 3D mould corner (see the figure). The simulations are compared with the local fabric distortions observed during draping experiments.The paper reports results of such combined meso-macro modelling for a plain weave carbon fabric with spread yarns. The boundary conditions for a local meso-model are taken from the macro draping simulation. The fabric geometry is modelled with WiseTex and transferred to the finite element package. A hyperelastic constitutive model for the yarns (Charmetant – Boisse) is used in the meso-modelling; the model parameters are identified and validated in independent tension, shear, compaction and bending tests of the yarn and the fabric. The simulation reproduces local yarn slippage and buckling, for example, the yarn distortion on the 3D mould corner (see the figure). The simulations are compared with the local fabric distortions observed during draping experiments.

Irreversibility during forming process of woven reinforcements

Today, numerical simulations of shaping fibrous reinforcements are based on continuous material models that have been assumed to be nonlinear elastic (hypoelastic [1] or hyperelastic [2, 3]). Nevertheless, it is also believed that during the shaping process, there is a possible non reversibility of behavior that plays a significant role. In this work, we are interested in quantifying the importance of these phenomena by doing a group of tests (flexion, shear, compression) and then afterwards by proposing models compatible with the simulation of industrial parts when irreversibility is significant.Today, numerical simulations of shaping fibrous reinforcements are based on continuous material models that have been assumed to be nonlinear elastic (hypoelastic [1] or hyperelastic [2, 3]). Nevertheless, it is also believed that during the shaping process, there is a possible non reversibility of behavior that plays a significant role. In this work, we are interested in quantifying the importance of these phenomena by doing a group of tests (flexion, shear, compression) and then afterwards by proposing models compatible with the simulation of industrial parts when irreversibility is significant.

Prediction of wrinklings and porosities of thermoplastic composits after thermostamping

During thermoforming process, the consolidation deformation mode of thermoplastic prepregs is one of the key deformation modes especially in the consolidation step, where the two resin flow phenomena: resin percolation and transverse squeeze flow, play an important role. This occurs a viscosity behavior for consolidation mode. Based on a visco-hyper-elastic model for the characterization of thermoplastic prepregs proposed by Guzman, which involves different independent modes of deformation: elongation mode, bending mode with thermo-dependent, and viscoelastic in-plan shearing mode with thermo-dependent, a viscoelastic model completed with consolidation behavior will be presented in this paper. A completed three-dimensional mechanical behavior with compaction effect for thermoplastic pre-impregnated composites is constituted, and the associated parameters are identified by compaction test. Moreover, a seven-node prismatic solid-shell finite element approach is used for the forming simulation. To subdue transverse shear locking, an intermediate material frame related to the element sides is introduced in order to fix nodal transverse shear strain components. Indeed, the enhanced assumed strain method and a reduced integration scheme are combined offering a linear varying strain field along the thickness direction to circumvent thickness locking, and an hourglass stabilization procedure is employed in order to correct the element’s rank deficiency for pinching. An additional node is added at the center providing a quadratic interpolation of the displacement in the thickness direction. The predominance of this element is the ability of three dimensional analysis, especially for the transverse stress existence through the thickness of material, which is essential for the consolidation modelling. Finally, an intimate contact model is employed to predict the evolution of the consolidation which permits the microstructure prediction of void presented through the prepreg. Several tests including a thermoforming test are launched to evaluate the consolidation model and the accuracy of the proposed element.During thermoforming process, the consolidation deformation mode of thermoplastic prepregs is one of the key deformation modes especially in the consolidation step, where the two resin flow phenomena: resin percolation and transverse squeeze flow, play an important role. This occurs a viscosity behavior for consolidation mode. Based on a visco-hyper-elastic model for the characterization of thermoplastic prepregs proposed by Guzman, which involves different independent modes of deformation: elongation mode, bending mode with thermo-dependent, and viscoelastic in-plan shearing mode with thermo-dependent, a viscoelastic model completed with consolidation behavior will be presented in this paper. A completed three-dimensional mechanical behavior with compaction effect for thermoplastic pre-impregnated composites is constituted, and the associated parameters are identified by compaction test. Moreover, a seven-node prismatic solid-shell finite element approach is used for the forming simulation. To subdue tra...

Hot forming of composite prepreg: Numerical analyses

The work presented here is part of the “FORBANS” project about the Hot Drape Forming (HDF) process consisting of unidirectional prepregs laminates. To ensure a fine comprehension of this process a combination strategy between experiment and numerical analysis is adopted. This paper is focused on the numerical analysis using the finite element method (FEM) with a hyperelastic constitutive law. Each prepreg layer is modelled by shell elements. These elements consider the tension, in-plane shear and bending behaviour of the ply at different temperatures. The contact/friction during the forming process is taken into account using forward increment Lagrange multipliers.

Meso F.E. simulation of composite reinforcement deformation based on X-ray computed tomography

Meso-FE modelling of 3D textile composites is a powerful tool, which can help determine mechanical properties and permeability of the reinforcements or composites. The quality of the meso FE analyses depends on the quality of the initial model. A direct method based on X-ray tomography imaging is introduced to determine finite element models based on the real geometry of 3D composite reinforcements. The method is particularly suitable regarding 3D textile reinforcements for which internal geometries are numerous and complex. An analysis of the image’s texture is performed. A hyperelastic model developed for fibre bundles is used for the simulation of the deformation of the 3D reinforcement.Meso-FE modelling of 3D textile composites is a powerful tool, which can help determine mechanical properties and permeability of the reinforcements or composites. The quality of the meso FE analyses depends on the quality of the initial model. A direct method based on X-ray tomography imaging is introduced to determine finite element models based on the real geometry of 3D composite reinforcements. The method is particularly suitable regarding 3D textile reinforcements for which internal geometries are numerous and complex. An analysis of the image’s texture is performed. A hyperelastic model developed for fibre bundles is used for the simulation of the deformation of the 3D reinforcement.

Viscous and thermal modelling of thermoplastic composites forming process

Thermoforming thermoplastic prepregs is a fast manufacturing process. It is suitable for automotive composite parts manufacturing. The simulation of thermoplastic prepreg forming is achieved by alternate thermal and mechanical analyses. The thermal properties are obtained from a mesoscopic analysis and a homogenization procedure. The forming simulation is based on a viscous-hyperelastic approach. The thermal simulations define the coefficients of the mechanical model that depend on the temperature. The forming simulations modify the boundary conditions and the internal geometry of the thermal analyses. The comparison of the simulation with an experimental thermoforming of a part representative of automotive applications shows the efficiency of the approach.

Advanced 3D textile composites reinforcements meso F.E analyses based on X-ray computed tomography

Meso-FE modelling of 3D textile composites is a powerful tool, which can help determine mechanical properties and permeability of the reinforcements or composites. The quality of the meso FE analyses depends on the quality of the initial model. A direct method based on X-ray tomography imaging is introduced to determine finite element models based on the real geometry of 3D composite reinforcements. The method is particularly suitable regarding 3D textile reinforcements for which internal geometries are numerous and complex. The approach used for the separation of the yarns in different directions is specialized because the fibres flow in three-dimensional space. An analysis of the image’s texture is performed. A hyperelastic model developed for fibre bundles is used for the simulation of the deformation of the 3D reinforcement.