Capabilities of macroscopic forming simulation for large-scale forming processes of dry and impregnated textiles

Forming of continuously fibre-reinforced polymers (CoFRP) has a significant impact on the structural performance of composite components, underlining the importance of forming simulation for CoFRP product development processes. For an integrated development of industrial composite components, efficient forming simulation methods are in high demand. Application-oriented method development is particularly crucial for industrial needs, where large and complex multi-layer components are manufactured, commercial FE software is used, and yet high prediction accuracy is required. To meet industrial demands, this contribution gives an insight in macroscopic forming simulation approaches that utilize the FE software Abaqus in combination with user-defined material models and finite elements. Three CoFRP forming technologies are considered, which are in industrial focus due to their suitability for mass production: textile forming of dry unidirectional non-crimp fabrics (UD-NCF), thermoforming of pre-impregnated UD tapes and wet compression moulding (WCM). In addition to the highly anisotropic, large-strain material behaviour that composite forming processes have in common, the three process technologies face various process-specific modelling challenges. UD-NCFs require material models that capture the deformation behaviour and the slippage of the stitching. Thermoforming of UD tapes is highly rate- and temperature-dependent, calling for rheological membrane and bending modelling. Moreover, a thermomechanical approach including crystallisation kinetics enables the prediction of potential phase-transition during forming and resulting defects in the semi-crystalline thermoplastic matrix. For simultaneous forming and infiltration in wet compression moulding, a finite Darcy-Progression-Element is superimposed with the membrane and shell elements for forming simulation, capturing infiltration-dependent material properties. The three outlined technologies illustrate the complexity and importance of further simulation method development to support future process development