Modelling the forming of tailored fibre placement preforms: A tetrahedral part with final orthotropic orientations

Modelling the forming of tailored fibre placement preforms: A tetrahedral part with final orthotropic orientations

SIMON Jessy, HAMILA Nahiene, BINÉTRUY Christophe, COMAS-CARDONA Sébastien

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Abstract. Forming of conventional reinforcements to manufacture 3D fibre-reinforced composite parts with complex geometries is limited by the architecture of the reinforcement made of initially straight fibres. On the opposite preforms obtained by Tailored Fibre Placement (TFP) are made of curvilinear fibre tows maintained on a backing material through stitching. In theory, the degree of freedom offered by TFP allows to form doubly-curved parts from preforms whose designs are determined from the desired final fibre orientations. In practice, it requires numerical tools to determine the design of the flat TFP preforms from the desired 3D parts, known as flattening. However, flattening is a virtual process which cannot be validated directly. Besides, the behavior of TFP preforms during forming has never been studied. Consequently, developing a numerical model to predict the formability of TFP preforms was considered as of first importance. Moreover, numerical forming can be required in a flattening algorithm [1]. Based on the Finite Element Method, a TFP preform is modelled at the fibre tows scale using 2-node beam elements. The stitching yarn, which ensures the cohesion of the layers, is modelled implicitly using an embedded element approach. The backing material is removed. A full-scale simulation of forming is experimentally validated. A tetrahedral shape, which corresponds to a corner bracket, is used to demonstrate the potential of TFP preform forming. An orthotropic design of the final part is achieved without defects using a simple forming device, which represents important progress in the field [2].

Keywords
Tailored Fibre Placement, Forming, Finite Element, Orthotropic Design

Published online 4/19/2023, 8 pages
Copyright © 2023 by the author(s)
Published under license by Materials Research Forum LLC., Millersville PA, USA

Citation: SIMON Jessy, HAMILA Nahiene, BINÉTRUY Christophe, COMAS-CARDONA Sébastien, Modelling the forming of tailored fibre placement preforms: A tetrahedral part with final orthotropic orientations, Materials Research Proceedings, Vol. 28, pp 231-238, 2023

DOI: https://doi.org/10.21741/9781644902479-25

The article was published as article 25 of the book Material Forming

Content from this work may be used under the terms of the Creative Commons Attribution 3.0 license. Any further distribution of this work must maintain attribution to the author(s) and the title of the work, journal citation and DOI.

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