Development of simulation methodology for virtual prototypes

Objectives

2

• Develop virtual manufacturing process for virtual

prototypes

• Eliminate number of real prototypes in design

process

Automated Draping Test Configuration at IFB

3

blank-holder

stamp

Pneumatic cylinders

mould

heating cartridge

Definition of draping process

4

Result at room temperature Result at 40°C after cool-down

• Almost no shearing at room temperature

• Strong spring-back effect, preform does not keep shape

• Higher temperatures could lead to improved drapability

Material tests for virtual process

5

• A simple test is performed to evaluate the shearing-behaviour of the

new textiles

• The simulation models can be calibrated based on the results

Draping simulation – state of the art (PamForm)

6

7

yarns resin

Draping simulation – new meso-scopic models

Resin

(Shells)Yarn 45°

(Shells)Yarn –45°

(Shells)Sewing Thread

(Bars)

Interface Resin-Yarn

(Tieds)

UD prepreg/semipreg biax semipreg

8

DoubleDome RT DoubleDome appr. 80°C

Draping simulation – new meso-scopic model for

UD prepreg material

9

Draping simulation – new meso-scopic model for

UD prepreg material

Failure appearing;

destruction of resin areas

Yarn directions

Draping simulation – new meso-scopic model

based on micro-scopic basic tests

1 test for characterizing shear behaviour

Draping simulation – new model based on micro-

scopic simulations

Forming simulation results

Tape laying / draping automatization support

12

• Automatic determination of required cut in initial ply

based on differences of lengths of sections on a tool

• Supporting information for automatic tape laying

system

Conclusion

13

• Several approaches of composite forming simulation

investigated to find the most suitable one for industrial

usage

• Validation of simulation results with experiment on

double-dome tool

• Due to identified parameters it is possible to simulate

curing cycle and part distortion