DRAPING SIMULATION

Recent achievements and future trends

Dr. Sylvain Bel – LGCIE – University Lyon 1

9/24/2014 Symposium – 5th anniversary LCC
DRAPING SIMULATION
Why ? How ? What ?
2
DRAPING SIMULATION – WHY ?

9/24/2014
Clamps

Symposium – 5th anniversary LCC

Punch

Fabric
Die
1 2 1 2

Resin

3 4
3 4
Fig. 1: Matched-Die Press forming Fig. 2: Matched-Die Press forming
for dry fabric before RTM for prepreg

Only a few examples of draping processes are given here. 3

Of course, also other draping processes exist as well!
 DRAPING SIMULATION – WHY ?

9/24/2014
Goals & Challenges:
— building of a complex shape (3D) without defects

Symposium – 5th anniversary LCC

— final fiber alignment should be suitable for structural
loads of the final part
— less or no cutting scrap (near-net shape preforming)
— high fiber volume content (final fiber distribution)
— low production cycle time
— high quality and reproducibility

[Hancock 2006]
DRAPING SIMULATION – WHY ?

9/24/2014
A combination of the deformation modes enables
the textile to be formed in a 3D shape

Symposium – 5th anniversary LCC

Transverse compression

Undeformed square of fabric

Bending

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Inter-ply movement
Elongation Shear
DRAPING SIMULATION – WHY ?

9/24/2014
A combination of the mesoscopic deformation
modes leads to macroscopic deformations

Symposium – 5th anniversary LCC

Fibre bending
Undeformed square
of woven fabric
Fibre buckling

Fibre straightening

Fibre Elongation Inter-fibre Shear Inter-fibre sliding

DRAPING SIMULATION – HOW ?

9/24/2014
The forming behavior of a homogenous material (e.g. metal sheet) can
be easily describe with Hooke’s Law. Describing the forming behavior
of a textile is not straight forward. The Young’s modulus and the
shear modulus of a textile are decoupled from each other. They are

Symposium – 5th anniversary LCC

not coupled via the Poisson’s ratio.

1 0
= 1 0
0 0 2(1 + ) 2
Hooke’s Law for Plane Stress for Homogenous Materials

? ?
= ? ?
? ? , 2
Constitutive Law for Plane Stress for Textiles 7

(“?” Matrix Entries are dependent on the type of textile)

 DRAPING SIMULATION – HOW ? Macro-level Approach

9/24/2014
To have a realistic textile behavior
suitable composite elements have to be chosen.

Symposium – 5th anniversary LCC

Composite Material Model
Composite Element PAM-FORM (ESI)

Shell Formulation
DRAPING SIMULATION – HOW ? Meso-level Approach

9/24/2014
The FE draping simulation at mesoscopic scale is based on common
2D/3D elements.

Symposium – 5th anniversary LCC

Ø Each yarn is modeled separately.

~ 105 DOF

~102 DOF

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[Hamila 2010]
DRAPING SIMULATION – WHAT ?

9/24/2014
Material characterization

Symposium – 5th anniversary LCC

Material modelling

Software development

Comparison - validation

Draping simulation
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DRAPING SIMULATION – WHAT ?

9/24/2014
Symposium – 5th anniversary LCC
∗
. cos sin .
2 2 2 2 2

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[Airbus Helicopters] [LCC/GE]

9/24/2014 Symposium – 5th anniversary LCC
DRAPING SIMULATION
Nowadays at the LCC
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 DRAPING OF THERMOPLASTIC PANELS

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• Thermoplastics sheets/panels
• Impregnated or comingled with thermoplastic resin
• Draped at high temperature (over temperature at melting point)

Symposium – 5th anniversary LCC

• Thermal dependency

[LCC] [LCC]
CF/PA6 : raw material, plate before and after consolidation

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1 2 3 4

Deep drawing for thermoplastic prepreg

DRAPING OF THERMOPLASTIC PANELS

9/24/2014
Symposium – 5th anniversary LCC
Parameters :
Composite Material Model
PAM-FORM (ESI) • Tension modulus
Composite • Shear modulus
Element
• Bending modulus
• Viscous behavior
• Thermal behavior
• Friction

Shell Formulation
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Investigations on the thermo-viscous behavior
DRAPING OF THERMOPLASTIC PANELS

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[Harrison 2004] : “Shear characterisation of viscous woven textile composites:
a comparison between picture frame and bias extension experiments”
ØPicture Frame test on Twill woven thermoplastic composite

Symposium – 5th anniversary LCC

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Reproducible test, no mention of folds or wrinkles
DRAPING OF THERMOPLASTIC PANELS

9/24/2014
Symposium – 5th anniversary LCC
[LCC] [LCC]
Picture Frame test on a CF/PA6 sheet at 280°C

• Wrinkles, almost from the start of the test 16

• Sliding, clamp pressure at high temperature
• Thermal expansion of the rig
DRAPING OF THERMOPLASTIC PANELS

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[Harrison 2013] : “Press forming a 0/90 cross-ply advanced thermoplastic
composite using the double-dome benchmark geometry”
ØPicture Frame test on uniaxial cross-ply sheet comprised of two
layers of unidirectional glass-PP plies, with a 0/90 initial fiber

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orientation

“Due to unavoidable misalignments, of the 35 tests that were conducted, only 7 were
found to meet [the following] conditions”

1. the result should be the lowest force curve produced under a given experimental
state (rate, temperature)
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2. the result can only be used up until wrinkling of the specimen is observed during
the test
3. the data should be physically consistent
9/24/2014 Symposium – 5th anniversary LCC
DRAPING SIMULATION
What’s coming next…
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MATERIAL CHARACTERIZATION :
THERMOPLASTICS COMPOSITE

9/24/2014
Symposium – 5th anniversary LCC
Single Cantilever Double Cantilever

Dynamic Mechanical 3 points bending (20mm) 3 points bending (50mm)

Analysis System 19

[Margossian2014]
MATERIAL CHARACTERIZATION :
THERMOPLASTICS COMPOSITE

9/24/2014
• Test method

o Setup: 3 point bending (20 mm)

o Specimen: 1mm thickness

Symposium – 5th anniversary LCC

• Procedures
o Procedure 1: Temperature influence
o Heat up to specified temperature at 10°C/min → 200°C,
220°C, 230°C, 240°C, 260°C, 280°C
o 5 minutes isothermal
o Quasistatic tests at 500 μm.min-1
o Procedure 2: Loading rate influence
o Heat up to 280°C at 10°C/min
o 5 minutes isothermal
o Quasistatic tests at specified loading rates → 100 μm.min-1,
500 μm.min-1, 1000 μm.min-1, 5000 μm.min-1, 10000 20
μm.min-1
[Margossian2014]
 MATERIAL CHARACTERIZATION :
THERMOPLASTICS COMPOSITE

9/24/2014
• Strong temperature and displacement rate dependencies → visco-elastic behaviour

Symposium – 5th anniversary LCC

• Inaccuracies in the application of the loading rates at the beginning of the test
are noticed for some cases (due to actuator accelaration)
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[Margossian2014]
THERMOPLASTICS AND PREPREG COMPOSITES

9/24/2014
Symposium – 5th anniversary LCC
[Wang2014, Lyon] [Harrison2013, Glasgow]

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[Sachs2014, Twente]
THERMOPLASTICS AND PREPREG COMPOSITES

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Material characterization of prepreg materials at forming temperature
ü Complex and attractive topic

Symposium – 5th anniversary LCC

ü Requires new methods

Material modeling of such materials is onerous

ü Time dependent
ü Temperature dependent

Software development should enable the thermoforming simulation

ü FE modeling with both mechanical and thermal calculation ??

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9/24/2014 Symposium – 5th anniversary LCC
THANK YOU FOR YOUR ATTENTION
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 BIBLIOGRAPHY

9/24/2014
¢ [Hancock 2006] The use of kinematic drape modeling to inform the hand lay-up of
complex composite components using woven reinforcements, Composite Part A, 2006
¢ [Hamila 2010] Textile Composite Reinforcement forming simulation, Numerical
methods and simulation, 2010

Symposium – 5th anniversary LCC

¢ [Pickett 2011] Analysis and process simulation of textile structures, 2011
¢ [Boisse 2011] Simulation of wrinkling during textile composite reinforcement
forming. Influence of tensile, in-plane shear and bending stiffnesses, Composites
Science and Technology, 2011
¢ [Harrison 2004] Shear characterisation of viscous woven textile composites: a
comparison between picture frame and bias extension experiments, Composites
Science and Technology, 2004
¢ [Harrison 2013] Press forming a 0/90 cross-ply advanced thermoplastic composite
using the double-dome benchmark geometry , Composites Part A, 2013
¢ [Margossian2014] Flexural characterisation of unidirectional thermoplastic tapes
using dynamic mechanical analysis, ECCM, 2014
¢ [Wang2014] Thermo-mechanical behavior of stretch-broken carbon fiber and
thermoplastic resin composites during manufacturing, Polymer Composites, 2014 25
¢ [Sachs2014] Bending characterisation of UD composites, 2014