Textile composite double dome stamping simulation using a non-orthogonal constitutive model

Stamping is one of the most effective ways to form textile composites in industry for providing high-strength, low-weight and cost-effective products. This paper presents a fully continuum mechanics-based approach for stamping simulation of textile fiber reinforced composites by using finite element (FE) method. A previously developed non-orthogonal constitutive model is used to represent the anisotropic mechanical behavior of textile composites under large deformation during stamping. Simulation are performed on a balanced plain weave composite with 0°/90° and ±45° as initial yarn orientation over a benchmark double dome device. Simulation results show good agreement with experimental output in terms of a number of parameters selected for comparison. The effects of meshing and shear moduli obtained from bias extension test and picture frame test on forming simulation results are also investigated.     

Particle filtration and distribution during the liquid composite molding process for manufacturing particles containing composite materials

The effects of major process parameters on particle filtration and distribution were investigated by using newly developed microscopic methodology using an electron probe micro-analyzer and numerical simulation. The mapping results indicated that well-dispersed particles were distributed uniformly in the inter-tow and intra-tow regions. Agglomerates were likely to be filtered at the boundary or inside of the fiber bundle. The results of quantitative analyses showed particle concentrations in the inter-tow region to be uniform throughout the composite part, whereas the intra-tow concentrations varied according to particle size and fiber orientation. The poor dispersion state of the CNT-Ag particles resulted in quite irregular distributions. A high volume fraction of the fiber preform resulted in a lower particle concentration inside the fiber tow. Numerical analysis of the filtration of large clusters of particles indicated that filtration occurred in the initial stage of the injection process at the tow boundaries.     

Modeling compressive response of 3D woven textile composites accounting for microscale geometric uncertainties

The compressive response of 3D woven textile composites (3DWTC), that consist of glass fiber tows and an epoxy matrix material, is studied using a finite element (FE)-based mechanics model. A parametric Representative Unit Cell (RUC) model is developed in a fully three-dimensional setting with geometry and textile architecture for modeling the textile microstructure. The RUC model accounts for the nonlinear behavior of the fiber tows and matrix. The computational model is utilized to predict the compressive strength of 3DWTC and its dependence on various geometrical and material parameters. The finite element model is coupled with a probabilistic analysis tool to provide probabilistic estimates for 3DWTC compressive strength. The reported results are found to be in good agreement with experimental data.     

纺织复合材料预制体成型过程无损检测技术研究进展

纺织复合材料多为各向异性材料,其力学性能很大程度上取决于成型后预制体内纤维的取向.为确保预制体成型后纤维的取向符合产品设计的要求,目前已有多种无损检测技术为纺织复合材料预制体成型过程及质量的检测提供服务.本文结合纺织复合材料预制体织造技术的发展趋势及预制体成型过程对无损检测的需求,就目前广泛用于科研和产业化生产当中的多...     

Discrete mesoscopic modeling for the simulation of woven-fabric reinforcement forming

A discrete modeling approach is proposed to simulate woven-fabric reinforcement forming via explicit finite element analysis. The tensile behaviour of the yarns is modeled by truss, beam or seatbelt elements, and the shearing behaviour of the fabric is incorporated within shell or membrane elements. This method is easy to set up using the user-defined material subroutine capabilities of explicit finite element programs. In addition, the determination of the material parameters is straightforward from conventional tensile and shear-frame tests. The proposed approach has been implemented in the ABAQUS and LS-DYNA explicit finite element programs. Two types of fabric, a plain-weave and a twill-weave Twintex® (commingled polypropylene and glass fibres) were characterized and used to validate the modeling approach. For this validation, shear-frame and bias-extension tests have been modeled, and the finite element results are compared to experimental data. The determination of experimental shear angle contours was possible via Digital Image Correlation (DIC). The finite element results from ABAQUS and LS-DYNA are similar and agree well with the experimental data. As an example of the capabilities of the method, the deep drawing of a hemisphere is simulated using both finite elements programs.     

Heterogeneously structured conductive carbon fiber composites by using multi-scale silver particles

This paper reports a new approach to enhance the through-thickness thermal conductivity of laminated carbon fabric reinforced composites by using nanoscale and microscale silver particles in combination to create heterogeneously structured continuous through-thickness thermal conducting paths. High conductivity of 6.62 W/(m K) with a 5.1 v% silver volume fraction can be achieved by incorporating these nanoscale and microscale silver particles in EWC-300X/Epon862 composite. Silver flakes were distributed within the inter-tow area, while nanoscale silver particles penetrated into the fiber tows. The combination of different sizes of silver fillers is able to effectively form continuous through-thickness conduction paths penetrating fiber tows and bridging the large inter-tow resin rich areas. Positive hybrid effects to thermal conductivity were found in IM7/EWC300X/sliver particle hybrid composites. In addition, microscale fillers in resin rich areas showed less impact on tensile performance than nanoscale particles applied directly on fiber surface.     

FEM modeling of multilayered textile composites based on shell elements

The paper presents a shell element based unit cell approach for numerical homogenization of fiber reinforced textile laminates. The modeling strategy is set up within the framework of the Finite Element Method. Multilayer laminates comprising equal weaves are considered and the constituents, i.e. the tows as well as the unreinforced matrix pockets are discretized by shell elements only which are coupled appropriately. A study on the effective extensional laminate-shell stiffnesses is presented, the results are discussed, and are compared to approaches found in the literature. Additionally, geometrically nonlinear simulations are conducted and the results are compared with experimental tests from literature.     

Mapping of preform architecture for textile reinforced composite products

In this paper, a technique is developed to map the internal fabric preform structure of textile composite products. This technique is based on physical serial sectioning of the composite product. Image analysis and manual yarn recognition are used to identify yarn location in each section. Image stereology is utilized to reconstruct the fabric preform in 3-D space. Data regarding average yarn orientation throughout the composite part are then extracted. This technique is applied to map the internal fabric preform structure of a proprietary textile reinforced composite product. Experimental work points to locations of fabric distortions that occur during the composite product manufacture. This technique could be extended to evaluate the effect of these distortions on the final composite properties.     

Modeling the Response of 3D Textile Composites under Compressive Loads to Predict Compressive Strength

The compression response of 3D woven textile composites (3DWC) that consist of glass fiber tows and a polymer matrix material is studied using a combination of experiments and finite element based analyses. A previous study reported by the authors consisted of an experimental investigation of 3DWC under high strain rate loading, Pankow, Salvi, Waas, Yen, and Ghiorse (2011). Those experimental results were explained by using the finite element method to analyze the high rate deformation response of representative volume elements (RVEs) of the 3DWC, Pankow, Waas, Yen, and Ghiorse (2012). In this paper, the same modeling strategy is used to examine the quasi-static, compressive deformation response of 3DWC. The effect of using different numbers of the textile repeat unit architecture in the RVE, on the predicted compression strength, is examined. The transitions in failure modes that are seen in experiments are seen to be captured by the model that is presented here.     

Preform permeability variation with porosity of fiberglass and carbon mats

An experimental investigation on fiber bed permeability variation with porosity for three types of reinforcement mats is performed. The reinforcements consist of plain-weave carbon, plain-weave fiberglass, and chopped fiberglass mats. Resin flow experiments are performed in a rectangular cavity with different fiber volume fractions. RL 440 epoxy resin is used as the working fluid in the experiments. Several layers of mats are laid inside the mold in each experiment and resin is injected at a constant pressure. The effects of reinforcement type and porosity on fiber bed permeability are investigated. Fiber mat permeability of woven mats show large degrees of anisotropy. Resin flow in chopped fiberglass mats is circular, suggesting an isotropic permeability tensor. In all the three cases, preform permeability increases with fiber bed porosity in a non-linear fashion. The results of this investigation could be employed in optimization of liquid composite molding manufacturing processes.     

Analysis of Laminated and Sandwich Composite Structures Using Solid-like Shell Elements

A new solid-like shell element was formulated which is suitable for analysis of laminated and sandwich composite structures. Then, a multiscale analysis technique was implemented to the shell element formulation so that micro-level stresses and strains (i.e. stresses and strains in reinforcing fibers and the binding matrix) in those structures can be computed. The shell element has three displacement degrees of freedom per node like a 3-D solid element. Therefore, the shell elements can be stacked easily on top of one another like 3-D solid elements in order to represent multiple layers through the thickness of laminated and sandwich structures. The effect of a thin resin or adhesive layer in laminated and sandwich composite structures was investigated on both static and the dynamic responses of the structures using the developed shell elements. The study showed an apparent effect of the resin/adhesive layer even though it is very thin. As a result, the present shell element can be used effectively to include those thin layers in finite element analysis models of laminated and sandwich composite structures.     

Longitudinal permeability determination of dual-scale fibrous materials

In this work, the longitudinal permeability of squarely packed dual-scale fiber preforms is studied theoretically. These fiber preforms are composed of aligned porous tows and the tows are tightly packed. The effective permeability is calculated as a parallel-like network of intra-tow permeability and inter-tow permeability, which are quantified by Darcy’s law and the inscribed radius between tows, respectively. The jump velocity at the interface between inter-tow fluids and porous tows is considered, as derived by substituting Beavers and Joseph’s correlation into Brinkman’s equation. We further examine the effects of intra-tow permeability on the effective permeability of the fibrous system with three interface conditions: (1) interface velocity = 0, (2) interface velocity = mean intra-tow velocity, and (3) interface velocity = jump velocity. The jump-velocity-based model is found to be closest to numerical data. The influence of the fiber volume fraction of tows on the effective permeability is also analyzed.     

Numerical homogenization of textile composites based on shell element discretization

The paper presents a shell element based unit cell approach for numerical homogenization of fiber reinforced textile composites. The modeling strategy is set up within the framework of the Finite Element Method with special emphasis on numerical efficiency, which becomes particularly important in the perspective of non-linear implicit simulations. A single layer of fabric is considered and the tows as well as the unreinforced matrix pockets are discretized by shell elements which are coupled appropriately allowing for delamination between the constituents. The approach is discussed, and the linear as well as the geometrical non-linear mechanical response of an example fabric is compared to a continuum based discretization of the same fabric. Additionally, simulations including delaminations are conducted. The substantially improved numerical efficiency of the shell based approach is shown.     

Transverse Tensile Properties of 3 Dimension-4 Directional Braided C<Subscript>f</Subscript>/SiC Composite Based on Double-Scale Model

In this thesis, a double-scale model for 3 Dimension-4 directional(3D-4d) braided C/SiC composites(CMCs) has been proposed to investigate mechanical properties of it. The double-scale model involves micro-scale which takes fiber/matrix/porosity in fibers tows into consideration and the unit cell scale which considers the 3D-4d braiding structure. Basing on the Micro-optical photographs of composite, we can build a parameterized finite element model that reflects structure of 3D-4d braided composites. The mechanical properties of fiber tows in transverse direction are studied by combining the crack band theory for matrix cracking and cohesive zone model for interface debonding. Transverse tensile process of 3D-4d CMCs can be simulated by introducing mechanical properties of fiber tows into finite element of 3D-4d braided CMCs. Quasi-static tensile tests of 3D-4d braided CMCs have been performed with PWS-100 test system. The predicted tensile stress-strain curve by the double scale model finds good agreement with the experimental results.     

Z-pin增强陶瓷基复合材料I型应变能释放率

碳纤维平纹编织物和碳纤维Z-pin制备的预成型体,通过化学气相渗透(CVI)工艺制成Z-pin增强平纹编织陶瓷基复合材料层压板。通过双悬臂梁试验研究Z-pin增强平纹编织陶瓷基复合材料层压板的层间I型应变能释放率和增强机理。研究Z-pin面积密度对层间I型应变能释放率的影响。结果表明:Z-pin增强平纹编织陶瓷基复合材料层压板主要增强机理表现为层间裂纹扩展受阻,Z-pin与层压板界面解离,Z-pin桥联裂纹和Z-pin拔出;增大Z-pin面积密度,层间I型应变能释放率增大。     

Prediction of energy absorption in composite stiffeners

The energy absorption behavior of composite stiffeners subjected to axial compression has been investigated. Flat plate, angle, and channel specimens were fabricated of T650-35/F584 graphite/epoxy plain-weave fabric and were crush tested under axial compression. A nonlinear finite element approach was used to model the sustained crushing of the flat plate specimens, and a progressive failure model was implemented as part of the finite element analysis to enable investigation of the fundamental mechanisms involved in the crushing behavior. The progressive failure model was based on linear elastic fracture mechanics for prediction of crack growth and a set of failure criteria for predicting fiber/matrix failures that occurred as a result of large deformations. Friction between the specimen and the crushing surface was included in the model. A semi-empirical analysis methodology was developed for prediction of the energy absorption capability of composite stiffeners based on crush tests of flat plate specimens and an understanding of the fundamentals of the energy absorption process.     

A system for the automatic generation of solid models of woven structures

Visualisation of complex 3D textile structures used to reinforce advanced composite materials can be extremely difficult. 3D models to assist in visualisation are recognised as being very helpful. In addition they can be used as the basis for parametric studies and finite element analysis, although the latter downstream use puts considerable demands upon the solid model.This paper describes a novel technique to automatically generate a parametric solid model of a woven textile reinforced composite material. The solid model is generated using a program file written in I-deas^® Open Language. The input data, provided by the user, describes the cross-sectional shape of tows. The system uses this data to automatically generate a set of basic tow ‘parts’. It then proceeds to put these together in a fabric assembly with appropriate constraints assuring the correct relative positions of the interlacing yarns.This assembly model of the tows constitutes the representative volume element, RVE, of the fabric structure. To demonstrate the principle, the approach is applied to the modelling of a 2D plain weave structure.     

Some aspects of numerical simulation for Lamb wave propagation in composite laminates

Some aspects of numerical simulation of Lamb wave propagation in composite laminates using the finite element models with explicit dynamic analysis are addressed in this study. To correctly and efficiently describe the guided-wave excited/received by piezoelectric actuators/sensors, effective models of surface-bounded flat PZT disks based on effective force, moment and displacement are developed. Different finite element models for Lamb wave excitation, collection and propagation in isotropic plate and quasi-isotropic laminated composite are evaluated using continuum elements (3-D solid element) and structural elements (3-D shell element), to elaborate the validity and versatility of the proposed actuator/sensor models.     

复合材料层合锥柱结合壳的有限元强度分析

本文应用各向异性层合壳体理论的有限元位移法对层合锥柱结合壳进行了强度分析。给出了各向同性锥柱结合壳和复合材料层合维柱结合壳的数值结果。各向同性锥柱结合壳的数值结果和三维弹性理论的有限元法计算结果作了比较,两者符合得很好。复合材料层合锥柱结合壳的数值结果也和用轴对称曲壳单元程序的计算结果作了比较,两者也很一致。      

考虑接头作用的全复合材料桁架结构多尺度分析

为提高全复合材料桁架分析的精度和效率,引入结构多尺度有限元思想,对接头进行精细化建模,通过建立两点位移约束实现不同尺度模型连接,从而将接头模型嵌入宏观桁架模型,并针对具体制备工艺赋予桁架材料属性。为验证多尺度模型的优势,同时进行全复合材料桁架实验,以及分别基于全部梁单元模型和全部实体单元模型的有限元分析。对比相关模型的计算精度与效率,结果表明多尺度模型能够较好地兼顾计算精度与效率。该文针对全复合材料桁架的结构多尺度有限元建模方法,可精确分析全复合材料桁架承载性能,并且能够提供有效的局部信息,可用于分析其他包含复杂细节构造的大尺度复合材料结构。