Sylvain Bel

Analyses of the Deformation Mechanisms of Non-Crimp Fabric Composite Reinforcements during Preforming

Two experimental devices are used for the analysis of the deformation mechanisms of biaxial non-crimp fabric composite reinforcements during preforming. The bias extension test, commonly use for the shear behaviour characterisation of woven fabrics, allows to highlight the sliding between the two plies of the reinforcement. This sliding is localized in areas of high gradient of shearing. This questions the use of bias extension test in determining the shear stiffness of the studied reinforcement. Then a hemispherical stamping experiment, representative of a preforming process, allows to quantify this sliding. The slippage is defined as the distance, projected onto the middle surface, of two points initially opposed on both sides of the reinforcement. For both experiments, the characteristic behavior of the non-crimp fabric reinforcement is highlighted by comparison with a woven textile reinforcement. This woven fabric presents only a very little sliding between warp and weft yarns during preforming. This aspect of the deformation kinematics of the non-crimp fabric reinforcement must be considered when simulating the preforming.

Forming Simulation of Thick AFP Laminates and Comparison with Live CT Imaging

Automated fiber placement (AFP) process can be used to manufacture laminates by laying up unidirectional slit tapes along a desired path and placing multiple layers on top of each other. Usually, the slit tapes are placed direct onto the tooling to attain the final part geometry. Alternatively, the laminate can be built up on a planar substrate and can be subsequently formed into the final shape. This kind of processing allows manufacturing highly curved parts, which may not be possible with the direct placement. In the present work a forming simulation of thick AFP laminates is developed to predict the tapes’ orientations and delamination as well as transverse tape spread-ups and separations during the forming process. The simulation model is built up through the material characterization experiments. Validation is performed comparing the results of the simulation vs. the experimental forming on two generic geometries. An optical inspection is made on the external layers of the laminates. In a second step, live computer tomography (CT) scans are used to inspect the tapes within an AFP laminate during forming of an L- and a Z-flange. Tapes re-orientation, gaps and tapes widening are observed experimentally and compared to the simulation results. The simulation is capable to predict the tows orientation and provides indicators concerning the tows spread-up and separation.

Characterisation of Tensile Properties Perpendicular to Fibre Direction of a Unidirectional Thermoplastic Composite Using a Dynamic Mechanical Analysis System

The ability of a draping simulation to accurately predict the outcome of a forming process mainly depends on the accuracy of the input parameters. For pre-impregnated composites, material must be characterised in the same conditions as forming occurs, i.e. in temperature regulated environment. Given the issues encountered while testing specimens enclosed in a thermal chamber and mounted on a tensile testing machine, new test methods have to be developed. A new approach using a Dynamic Mechanical Analysis system is presented for the investigation of tensile properties perpendicular to fibre direction of unidirectional pre-impregnated composites. Analyses are focused on a unidirectional carbon fibre thermoplastic tape reinforced polyamide 6 in its molten state. Quasi-static tests are performed at forming temperature for different loading rates with specimens of different geometries in order to assess the reproducibility of the test method.

On the modeling of separation foils in thermoforming simulations

Composite forming simulations consist in modelling the forming process of composite components to anticipate the occurrence of potential flaws such as out-of-plane wrinkles and fibre re-orientation. Forming methods often consist of automated processes in which flat composite blanks are forced to comply with tool geometries. Although Finite Element forming simulations require the modelling of all stakeholders (blankholder, tooling and composite blank), consumables such as separation films are often not considered. Used in thermoforming processes, these films are placed between tooling and composite to ease part removal after forming. These films are also used to decrease tool/ply friction and thus, enhance forming quality. This work presents thermoforming simulations of pre-impregnated carbon fibre thermoplastic blanks in which separation films are modelled in the same manner as composite layers, i.e. by a layer of shell elements. The mechanical properties of such films are also characterised at the same t...

Analysis of Non-Crimp Fabric Composite Reinforcements Forming

Abstract Two experimental devices are used for the analysis of the deformation mechanisms of biaxial non-crimp fabric composite reinforcements during preforming. The bias extension test, commonly use for the shear behaviour characterisation of woven fabrics, allows to highlight the sliding between the two plies of the reinforcement. This sliding is localized in areas of high gradient of shearing. This questions the use of bias extension test in determining the shear stiffness of the studied reinforcement. Then a hemispherical stamping experiment, representative of a preforming process, allows to quantify this sliding. The slippage is defined as the distance, projected onto the middle surface, of two points initially opposed on both sides of the reinforcement. For both experiments, the characteristic behavior of the non-crimp fabric reinforcement is highlighted by comparison with a woven textile reinforcement. This woven fabric presents only a very little sliding between warp and weft yarns during preforming. This aspect of the deformation kinematics of the non-crimp fabric reinforcement must be considered when simulating the preforming.