Experimental Characterization and Numerical Modeling of the Interaction Between Carbon Fiber Composite Prepregs During a Preforming Process

Zhang, Weizhao; Ma, Xuan; Lu, Jie; Zhang, Zixuan; Jane Wang, Q.; Su, Xuming; Zeng, Danielle; Mirdamadi, Mansour; Cao, Jian

doi:10.1115/1.4039979

Experimental Characterization and Numerical Modeling of the Interaction Between Carbon Fiber Composite Prepregs During a Preforming Process

Journal Article · Mon May 21 00:00:00 EDT 2018 · Journal of Manufacturing Science and Engineering

DOI:https://doi.org/10.1115/1.4039979· OSTI ID:1504734

Zhang, Weizhao ^[1]; Ma, Xuan ^[2]; Lu, Jie ^[3]; Zhang, Zixuan ^[3]; Jane Wang, Q. ^[3]; Su, Xuming ^[4]; Zeng, Danielle ^[4]; Mirdamadi, Mansour ^[5]; Cao, Jian ^[3]

Northwestern Univ., Evanston, IL (United States); Northwestern University
Northwestern Univ., Evanston, IL (United States); Harbin Inst. of Technology (China)
Northwestern Univ., Evanston, IL (United States)
Ford Motor Company, Dearborn, MI (United States)
Dow Chemical Company, Auburn Hills, MI (United States)

We report carbon fiber reinforced composites have received growing attention because of their superior performance and high potential for lightweight systems. An economic method to manufacture the parts made of these composites is a sequence of forming followed by a compression molding. The first step in this sequence is called preforming that forms the prepreg, which is the fabric impregnated with the uncured resin, to the product geometry, while the molding process cures the resin. Slip between different prepreg layers is observed in the preforming step, and it is believed to have a non-negligible impact on the resulting geometry. This paper reports a method to characterize the interaction between different prepreg layers, which should be valuable for future predictive modeling and design optimization. An experimental device was built to evaluate the interactions with respect to various industrial production conditions. The experimental results were analyzed for an in-depth understanding about how temperature, relative sliding speed, and fiber orientation affect the tangential interaction between two prepreg layers. Moreover, a hydro-lubricant model was introduced to study the relative motion mechanism of this fabric-resin-fabric system, and the results agreed well with the experiment data. Lastly, the interaction factors obtained from this research will be implemented in a preforming process finite element simulation model.

View Accepted Manuscript (DOE)

Research Organization:: Ford Motor Company, Dearborn, MI (United States)

Sponsoring Organization:: USDOE Office of Energy Efficiency and Renewable Energy (EERE), Vehicle Technologies Office (EE-3V)

Grant/Contract Number:: EE0006867

OSTI ID:: 1504734

Journal Information:: Journal of Manufacturing Science and Engineering, Journal Name: Journal of Manufacturing Science and Engineering Journal Issue: 8 Vol. 140; ISSN 1087-1357

Publisher:: ASMECopyright Statement

Country of Publication:: United States

Language:: English

References (34)

Recent advances in low-cost carbon fiber manufacture from lignin Baker, Darren A.; Rials, Timothy G. Journal of Applied Polymer Science, Vol. 130, Issue 2 https://doi.org/10.1002/app.39273	journal	April 2013
Micro-Textures in Concentrated Conformal-Contact Lubrication: Effects of Texture Bottom Shape and Surface Relative Motion Nanbu, Toshikazu; Ren, Ning; Yasuda, Yoshiteru Tribology Letters, Vol. 29, Issue 3 https://doi.org/10.1007/s11249-008-9302-9	journal	February 2008
Surface Texture Effect on Friction of a Microtextured Poly(dimethylsiloxane) (PDMS) He, Bo; Chen, Wei; Jane Wang, Q. Tribology Letters, Vol. 31, Issue 3 https://doi.org/10.1007/s11249-008-9351-0	journal	August 2008
Life cycle assessment of carbon fiber-reinforced polymer composites Das, Sujit The International Journal of Life Cycle Assessment, Vol. 16, Issue 3 https://doi.org/10.1007/s11367-011-0264-z	journal	February 2011
Numerical simulations on double-dome forming of woven composites using the coupled non-orthogonal constitutive model Lee, Wonoh; Cao, Jian International Journal of Material Forming, Vol. 2, Issue S1 https://doi.org/10.1007/s12289-009-0499-4	journal	August 2009
Discrete mesoscopic modeling for the simulation of woven-fabric reinforcement forming Jauffrès, David; Sherwood, James A.; Morris, Corey D. International Journal of Material Forming, Vol. 3, Issue S2 https://doi.org/10.1007/s12289-009-0646-y	journal	November 2009
A characterization of shear flow in continuous fibre thermoplastic laminates Groves, D. J. Composites, Vol. 20, Issue 1 https://doi.org/10.1016/0010-4361(89)90678-2	journal	January 1989
Inter- and intraply-slip flow processes during thermoforming of cf/pp-laminates Scherer, R.; Friedrich, K. Composites Manufacturing, Vol. 2, Issue 2 https://doi.org/10.1016/0956-7143(91)90185-J	journal	January 1991
Surface friction effects related to pressforming of continuous fibre thermoplastic composites Murtagh, Adrian M.; Lennon, John J.; Mallon, Patrick J. Composites Manufacturing, Vol. 6, Issue 3-4 https://doi.org/10.1016/0956-7143(95)95008-M	journal	January 1995
Prediction of fibre orientation and net shape definition of complex composite parts Trochu, F.; Hammami, A.; Benoit, Y. Composites Part A: Applied Science and Manufacturing, Vol. 27, Issue 4 https://doi.org/10.1016/1359-835X(95)00054-6	journal	January 1996
Mechanical behavior of carbon fiber reinforced polyamide composites Botelho, E. Composites Science and Technology, Vol. 63, Issue 13 https://doi.org/10.1016/S0266-3538(03)00119-2	journal	October 2003
Investigation of draping and its effects on the mold filling process during manufacturing of a compound curved composite part Bickerton, Simon; Šimáček, Pavel; Guglielmi, Sarah E. Composites Part A: Applied Science and Manufacturing, Vol. 28, Issue 9-10 https://doi.org/10.1016/S1359-835X(97)00033-X	journal	January 1997
Thermal conductivity enhancement of carbon fiber composites Wang, Moran; Kang, Qinjun; Pan, Ning Applied Thermal Engineering, Vol. 29, Issue 2-3 https://doi.org/10.1016/j.applthermaleng.2008.03.004	journal	February 2009
A non-orthogonal material model of woven composites in the preforming process Zhang, Weizhao; Ren, Huaqing; Liang, Biao CIRP Annals, Vol. 66, Issue 1 https://doi.org/10.1016/j.cirp.2017.04.112	journal	January 2017
Large deformation simulation of anisotropic material using an updated Lagrangian finite element method ten Thije, R. H. W.; Akkerman, R.; Huétink, J. Computer Methods in Applied Mechanics and Engineering, Vol. 196, Issue 33-34 https://doi.org/10.1016/j.cma.2007.02.010	journal	July 2007
A simplified finite element model for draping of woven material Sharma, S. B.; Sutcliffe, M. P. F. Composites Part A: Applied Science and Manufacturing, Vol. 35, Issue 6 https://doi.org/10.1016/j.compositesa.2004.02.013	journal	June 2004
Characterization of mechanical behavior of woven fabrics: Experimental methods and benchmark results Cao, J.; Akkerman, R.; Boisse, P. Composites Part A: Applied Science and Manufacturing, Vol. 39, Issue 6 https://doi.org/10.1016/j.compositesa.2008.02.016	journal	June 2008
A multi-layer triangular membrane finite element for the forming simulation of laminated composites ten Thije, R. H. W.; Akkerman, R. Composites Part A: Applied Science and Manufacturing, Vol. 40, Issue 6-7 https://doi.org/10.1016/j.compositesa.2009.03.004	journal	July 2009
Simulations of textile composite reinforcement draping using a new semi-discrete three node finite element Hamila, Nahiène; Boisse, Philippe Composites Part B: Engineering, Vol. 39, Issue 6 https://doi.org/10.1016/j.compositesb.2007.11.008	journal	September 2008
Thermoforming simulation of multilayer composites with continuous fibres and thermoplastic matrix Wang, Peng; Hamila, Nahiène; Boisse, Philippe Composites Part B: Engineering, Vol. 52 https://doi.org/10.1016/j.compositesb.2013.03.045	journal	September 2013
A simple anisotropic hyperelastic constitutive model for textile fabrics with application to forming simulation Peng, Xiongqi; Guo, Zaoyang; Du, Tongliang Composites Part B: Engineering, Vol. 52 https://doi.org/10.1016/j.compositesb.2013.04.014	journal	September 2013
Textile composite double dome stamping simulation using a non-orthogonal constitutive model Peng, Xiongqi; Rehman, Zia Ur Composites Science and Technology, Vol. 71, Issue 8 https://doi.org/10.1016/j.compscitech.2011.03.010	journal	May 2011
An anisotropic hyperelastic constitutive model for thermoplastic woven composite prepregs Gong, Youkun; Peng, Xiongqi; Yao, Yuan Composites Science and Technology, Vol. 128 https://doi.org/10.1016/j.compscitech.2016.03.005	journal	May 2016
Simulation of 3D interlock composite preforming De Luycker, E.; Morestin, F.; Boisse, P. Composite Structures, Vol. 88, Issue 4 https://doi.org/10.1016/j.compstruct.2008.06.005	journal	May 2009
Combination of Carbon Fibre Sheet Moulding Compound and Prepreg Compression Moulding in Aerospace Industry Wulfsberg, Jens; Herrmann, Axel; Ziegmann, Gerhard Procedia Engineering, Vol. 81 https://doi.org/10.1016/j.proeng.2014.10.197	journal	January 2014
A transient hydrodynamic lubrication model for piston/cylinder interface of variable length Ma, Xuan; Wang, Q. Jane; Lu, Xiqun Tribology International, Vol. 118 https://doi.org/10.1016/j.triboint.2017.09.035	journal	February 2018
An integrated computational materials engineering method for woven carbon fiber composites preforming process Zhang, Weizhao; Ren, Huaqing; Wang, Zequn ESAFORM 2016: Proceedings of the 19th International ESAFORM Conference on Material Forming, AIP Conference Proceedings https://doi.org/10.1063/1.4963592	conference	January 2016
A Simulation of the Draping of Bidirectional Fabrics over Arbitrary Surfaces van West, B. P.; Pipes, R. B.; Keefe, M. The Journal of The Textile Institute, Vol. 81, Issue 4 https://doi.org/10.1080/00405009008658722	journal	January 1990
39—The Fitting of Woven Cloth to Surfaces Mack, C.; Taylor, H. M. Journal of the Textile Institute Transactions, Vol. 47, Issue 9 https://doi.org/10.1080/19447027.1956.10750433	journal	September 1956
Virtual Texturing: Modeling the Performance of Lubricated Contacts of Engineered Surfaces Wang, Q. Jane; Zhu, Dong Journal of Tribology, Vol. 127, Issue 4 https://doi.org/10.1115/1.2000273	journal	May 2005
An Average Flow Model for Determining Effects of Three-Dimensional Roughness on Partial Hydrodynamic Lubrication Patir, Nadir; Cheng, H. S. Journal of Lubrication Technology, Vol. 100, Issue 1 https://doi.org/10.1115/1.3453103	journal	January 1978
Machining of Carbon Fiber Reinforced Plastics/Polymers: A Literature Review Che, Demeng; Saxena, Ishan; Han, Peidong Journal of Manufacturing Science and Engineering, Vol. 136, Issue 3 https://doi.org/10.1115/1.4026526	journal	March 2014
Processing of Composites: Simulations of the Draping of Fabrics with Updated Material Behaviour Law Dong, L.; Lekakou, C.; Bader, M. G. Journal of Composite Materials, Vol. 35, Issue 2 https://doi.org/10.1177/002199801772661975	journal	January 2001
Thermoforming-Stamping of Continuous Glass Fiber/Polypropylene Composites: Interlaminar and Tool–Laminate Shear Properties Lebrun, Gilbert; Bureau, Martin N.; Denault, Johanne Journal of Thermoplastic Composite Materials, Vol. 17, Issue 2 https://doi.org/10.1177/0892705704035411	journal	March 2004