development of simulation methodology for virtual · pdf file• develop virtual...
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Development of simulation methodology for virtual prototypes
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Objectives
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• Develop virtual manufacturing process for virtual
prototypes
• Eliminate number of real prototypes in design
process
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Automated Draping Test Configuration at IFB
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blank-holder
stamp
Pneumatic cylinders
mould
heating cartridge
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Definition of draping process
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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
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Material tests for virtual process
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• A simple test is performed to evaluate the shearing-behaviour of the
new textiles
• The simulation models can be calibrated based on the results
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Draping simulation – state of the art (PamForm)
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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
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DoubleDome RT DoubleDome appr. 80°C
Draping simulation – new meso-scopic model for
UD prepreg material
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Draping simulation – new meso-scopic model for
UD prepreg material
Failure appearing;
destruction of resin areas
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Yarn directions
Draping simulation – new meso-scopic model
based on micro-scopic basic tests
1 test for characterizing shear behaviour
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Draping simulation – new model based on micro-
scopic simulations
Forming simulation results
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Tape laying / draping automatization support
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• 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
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Conclusion
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• 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