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

download PDF

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].

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


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.

[1] X. Sun, J. P. -H. Belnoue, W.-T. Wang, B. C. Kim, S. R. Hallett, “Un-forming” fibre-steered preforms: Towards fast and reliable production of complex composites parts, Composi. Sci. Technol. 216 (2021) 109060. /10.1016/j.compscitech.2021.109060
[2] J. Simon, N. Hamila, C. Binetruy, S. Comas-Cardona, B. Masseteau, Design and numerical modelling strategy to form Tailored Fibre Placement preforms: Application to the tetrahedral part with orthotropic final configuration, Compos. Part A: Appl. Sci. Manuf. 158 (2022) 106952. /10.1016/j.compositesa.2022.106952
[3] A. Spickenheuer, M. Schulz, K. Gliesche, G. Heinrich, Using tailored fibre placement technology for stress adapted design of composite structures, Plastics, Rubber and Composites 37 (2008) 227-232.
[4] K. Uhlig, A. Spickenheuer, L. Bittrich, G. Heinrich, Development of a Highly Stressed Bladed Rotor Made of a CFRP Using the Tailored Fiber Placement Technology, Mech. Compos. Mater. 49 (2013) 201-210.
[5] K. Katagiri, S. Honda, S. Nakaya, T. Kimura, S. Yamaguchi, H. Sonomura, T. Ozaki, S. Kawakita, M. Takemura, K. Sasaki, Tensile strength of CFRP with curvilinearly arranged carbon fiber along the principal stress direction fabricated by the electrodeposition resin molding, Compos. Part A: Appl. Sci. Manuf. 143 (2021) 106271.
[6] P.J. Crothers, K. Drechsler, D. Feltin, I. Herszberg, T. Kruckenberg, Tailored fibre placement to minimise stress concentrations, Compos. Part A: Appl. Sci. Manuf. 28 (1997) 619-625.
[7] K. Gliesche, Application of the tailored fibre placement (TFP) process for a local reinforcement on an “open-hole” tension plate from carbon/epoxy laminates, Compos. Sci. Technol. 63 (2003) 81-88.
[8] E.G. Koricho, A. Khomenko, T. Fristedt, M. Haq, Innovative tailored fiber placement technique for enhanced damage resistance in notched composite laminate, Compos. Struct. 120 (2015) 378-385.
[9] H. M. El-Dessouky, M. N. Saleh, M. Gautam, G. Han, R. J. Scaife, P. Potluri, Tailored fibre placement of commingled carbon-thermoplastic fibres for notch-insensitive composites, Compos. Struct. 214 (2019) 348-358.
[10] K. Uhlig, A. Spickenheuer, K.Gliesche, I. Karb, Strength of CFRP open hole laminates made from NCF, TFP and braided preforms under cyclic tensile loading, Plastics, Rubber and Composites 39 (2010) 247-255.
[11] M. Takezawa, Y. Otoguro, K. Matsuo, T. Shibutani, A. Sakurai, T. Maekawa, Fabrication of doubly-curved CFRP shell structures with control over fiber directions, Comput.-Aided Design. 136 (2021) 103028.
[12] G. Rihaczek, M. Klammer, O. Başnak, J. Petrš, B. Grisin, H. Dahy, S. Carosella, P. Middendorf, Curved Foldable Tailored Fiber Reinforcements for Moldless Customized Bio-Composite Structures. Proof of Concept: Biomimetic NFRP Stools, Polymers 12 (2020).
[13] S. Allaoui, P. Boisse, S. Chatel, N. Hamila, G. Hivet, D. Soulat, E. Vidal-Salle, Experimental and numerical analyses of textile reinforcement forming of a tetrahedral shape, Compos. Part A: Appl. Sci. Manuf. 42) (2011) 612-622.
[14] P. Ouagne, D. Soulat, J. Moothoo, E. Capelle, S. Gueret, Complex shape forming of a flax woven fabric; analysis of the tow buckling and misalignment defect, Composites Part A: Applied Science and Manufacturing. 51 (2013) 1-10.
[15] M. Géradin, A. Cardona, Flexible Multibody Dynamics: A Finite Element Approach. Wiley-Blackwell, New York, 2001.
[16] M. Ritto-Corrêa, D. Camotim, On the differentiation of the Rodrigues formula and its significance for the vector-like parameterization of Reissner-Simo beam theory: Differentiation of Rodrigues formula, Int. J. Numer. Meth. Eng. 55) (2002) 1005-1032.
[17] A. Ibrahimbegović, F. Frey, I. Kožar, Computational aspects of vector-like parametrization of three-dimensional finite rotations, Int. J. Numer. Meth. Eng. 38 (1995) 3653-3673.