A review on process-induced distortions of carbon fiber reinforced thermosets for large-scale production

During the manufacturing process of carbon fiber reinforced plastics, residual stresses and shape distortions occur. Analytical or numerical models can be employed to accurately predict these stresses and deformations. For a virtual compensation of a part’s geometry, an understanding of the main driving mechanisms behind process-induced distortions is essential. The present study shows main sources as well as influencing factors on stresses and distortions that arise during large-scale production of composites based on thermoset resin systems. Besides basic information on the thermal, chemical and mechanical behavior of thermoset resins and carbon fibers, state-of-the-art numerical approaches are reviewed with a focus on finite element discretization and constitutive modeling. Current virtual compensation strategies as well as possible influences of the forming operation are discussed. Finally, a conclusion is drawn that includes recommendations for future developments in the field of process-induced distortions.