Simulation of the forming process for curved composite sandwich panels
Tóm tắt
For affordable high-volume manufacture of sandwich panels with complex curvature and varying thickness, fabric skins and a core structure are simultaneously press-formed using a set of matched tools. A finite-element-based process simulation was developed, which takes into account shearing of the reinforcement skins, multi-axial deformation of the core structure, and friction at the interfaces. Meso-scale sandwich models, based on measured properties of the honeycomb cell walls, indicate that panels deform primarily in bending if out-of-plane movement of the core is unconstrained, while local through-thickness crushing of the core is more important in the presence of stronger constraints. As computational costs for meso-scale models are high, a complementary macro-scale model was developed for simulation of larger components. This is based on experimentally determined homogenised properties of the honeycomb core. The macro-scale model was employed to analyse forming of a generic component. Simulations predicted the poor localised conformity of the sandwich to the tool, as observed on a physical component. It was also predicted accurately that fibre shear angles in the skins are below the critical angle for onset of fabric wrinkling.
Tài liệu tham khảo
PUR-CSM Technology, <https://www.hennecke.com/sites/default/files/downloads/purcsm_de_en.pdf>. Accessed July 2019
Bright Lite Structures, <https://www.blstructures.com/>. Accessed July 2019
Vehicle underbody structure with lightweight PU composite, <https://www.gupta-verlag.com/news/technology/9357/vehicle-underbody-structure-with-lightweight-pu-composite>. Accessed July 2019
BMS recommends polycarbonate core for PU sandwich composites, <https://utech-polyurethane.com/news/bms-recommends-polycarbonate-core-for-pu-sandwich-composites/>. Accessed July 2019
Sloan, J., JEC World 2019 preview: Huntsmand, <https://www.compositesworld.com/products/jec-world-2019-preview-huntsman(2)>. Accessed July 2019
Automotive interior resin system, <https://www.materialstoday.com/composite-processing/products/automotive-interior-resin-system/>. Accessed July 2019
Lightweight parts interior, <https://koller-gruppe.de/en/lightweight-parts-interior/>. Accessed July 2019
Gordon Murray Design, <www.iStreamtechnology.co.uk>. Accessed June 2017
Pflug, J., EconCore, Composite Panels: Thermoplastic Solution for Demanding Applications, <http://www.econcore.com/en/products-applications/composite-panels>. Accessed June 2017
Cai Z-Y, Zhang X, Liang X-B (2018) Multi-point forming of sandwich panels with egg-box-like cores and failure behaviors in forming process: analytical models, numerical and experimental investigations. Mater Des 160:1029–1041
Chen Z, Yan N, Sam-Brew S, Smith G, Deng J (2014) Investigation of mechanical properties of sandwich panels made of paper honeycomb core and wood composite skins by experimental testing and finite element (FE) modelling methods. Eur J Wood Wood Prod 72(3):311–319
Mozafari H, Khatami S, Molatefi H (2015) Out of plane crushing and local stiffness determination of proposed foam filled sandwich panel for Korean tilting train eXpress–numerical study. Mater Des 66:400–411
Gibson LJ, Ashby MF (1999) Cellular solids: structure and properties. Cambridge university press
Foo C, Chai G, Seah L (2008) A model to predict low-velocity impact response and damage in sandwich composites. Compos Sci Technol 68(6):1348–1356
Petras A, Sutcliffe M (1999) Failure mode maps for honeycomb sandwich panels. Compos Struct 44(4):237–252
Aktay L, Johnson AF, Holzapfel M (2005) Prediction of impact damage on sandwich composite panels. Comput Mater Sci 32(3–4):252–260
Chawla A, Mukherjee S, Kumar D, Nakatani T, Ueno M (2003) Prediction of crushing behaviour of honeycomb structures. Int j crashworthiness 8(3):229–235
Abrate S (1998) Impact on composite structures. Cambridge University Press, Cambridge
Burton WS, Noor A (1997) Structural analysis of the adhesive bond in a honeycomb core sandwich panel. Finite Elem Anal Des 26(3):213–227
Dear J, Lee H, Brown S (2005) Impact damage processes in composite sheet and sandwich honeycomb materials. Int J Impact Eng 32(1–4):130–154
Chen S, Endruweit A, Harper L, Warrior N (2015) Inter-ply stitching optimisation of highly drapeable multi-ply preforms. Compos A: Appl Sci Manuf 71:144–156
Chen S, Harper L, Endruweit A, Warrior N (2015) Formability optimisation of fabric preforms by controlling material draw-in through in-plane constraints. Compos A: Appl Sci Manuf 76:10–19
Chen S, McGregor O, Endruweit A, Elsmore M, De Focatiis D, Harper L, Warrior N (2017) Double diaphragm forming simulation for complex composite structures. Compos A: Appl Sci Manuf 95:346–358
Chen S, McGregor O, Harper L, Endruweit A, Warrior N (2016) Defect formation during preforming of a bi-axial non-crimp fabric with a pillar stitch pattern. Compos A: Appl Sci Manuf 91:156–167
Chen S, McGregor O, Harper L, Endruweit A, Warrior N (2018) Optimisation of local in-plane constraining forces in double diaphragm forming. Compos Struct 201:570–581
Yu W-R, Harrison P, Long A (2005) Finite element forming simulation for non-crimp fabrics using a non-orthogonal constitutive equation. Compos A: Appl Sci Manuf 36(8):1079–1093
Xue P, Peng X, Cao J (2003) A non-orthogonal constitutive model for characterizing woven composites. Compos A: Appl Sci Manuf 34(2):183–193
Peng X, Cao J (2005) A continuum mechanics-based non-orthogonal constitutive model for woven composite fabrics. Compos A: Appl Sci Manuf 36(6):859–874
Khan MA, Mabrouki T, Vidal-Sallé E, Boisse P (2010) Numerical and experimental analyses of woven composite reinforcement forming using a hypoelastic behaviour. Application to the double dome benchmark. J Mater Process Technol 210(2):378–388
Boisse P, Hamila N, Helenon F, Hagege B, Cao J (2008) Different approaches for woven composite reinforcement forming simulation. Int J Mater Form 1(1):21–29
Boisse P, Aimène Y, Dogui A, Dridi S, Gatouillat S, Hamila N, Khan MA, Mabrouki T, Morestin F, Vidal-Sallé E (2010) Hypoelastic, hyperelastic, discrete and semi-discrete approaches for textile composite reinforcement forming. Int J Mater Form 3(2):1229–1240
Boisse P, Hamila N, Helenon F, Aimene Y, Mabrouki T (2007) Draping of textile composite reinforcements: continuous and discrete approaches. Adv Compos Lett 3(4):125–131
Cao J, Akkerman R, Boisse P, Chen J, Cheng H, De Graaf E, Gorczyca J, Harrison P, Hivet G, Launay J (2008) Characterization of mechanical behavior of woven fabrics: experimental methods and benchmark results. Compos A: Appl Sci Manuf 39(6):1037–1053
Harrison P, Clifford MJ, Long A (2004) Shear characterisation of viscous woven textile composites: a comparison between picture frame and bias extension experiments. Compos Sci Technol 64(10–11):1453–1465
Dassault Systèmes, Abaqus (2016) Analysis User’s Guide. 2016