An Analytical Model for Wrinkle-free Forming of Composite Laminates

Alex Trenam; Chrysoula Aza; Christian Jones; Guy Lawrence; Lee Harper; Andrew T. Rhead; Evros Loukaides; Richard Butler

doi:10.1016/j.compositesa.2024.108386

An Analytical Model for Wrinkle-free Forming of Composite Laminates

Alex Trenam, Chrysoula Aza, Christian Jones, Guy Lawrence, Lee Harper, Andrew T. Rhead, Evros Loukaides, Richard Butler

University of Nottingham

Research output: Contribution to journal › Article › peer-review

Abstract

Double Diaphragm Forming (DDF) of 3D shapes significantly increases production rates for laminated composite parts when compared with Automated Fibre Placement. However, it is prone to the occurrence of wrinkling defects, which can lead either to concession of part strength or expensive and wasteful part scrappage. Finite element simulation of the process is computationally costly and not suited to preliminary design for manufacture. In this work a novel analytical model is presented, based on obtaining the wrinkle profile via energy minimisation using a Rayleigh–Ritz approach, which enables rapid mechanics-based assessment of formability for the design of wrinkle-free composite products. The new modelling approach is validated against eight experimental DDF forming trials performed over C-shaped tools with double curvature using both dry Non-Crimped Fabric and unidirectional prepreg material. The model successfully predicts the three cases for which wrinkling is absent and the five cases where it occurs.

Original language	English
Article number	108386
Number of pages	11
Journal	Composites Part A: Applied Science and Manufacturing
Volume	186
Early online date	3 Aug 2024
DOIs	https://doi.org/10.1016/j.compositesa.2024.108386
Publication status	E-pub ahead of print - 3 Aug 2024

Data Availability Statement

Data will be made available on request.

Acknowledgements

NCForm is led by Professor Michael Sutcliffe at the University of Cambridge, and we are particularly grateful for his many helpful contributions.

Funding

This work was funded by Design, Simulation Tools and Process Improvements for NCF Preforming (NCForm), UK, a Core project under the EPSRC Future Composites manufacturing Research Hub, UK (EP/P006701/1). Alex Trenam is supported by NCForm, UK and by a Ph.D. studentship from the EPSRC Centre for Doctoral Training in Advanced Automotive Propulsion Systems, UK (EP/S023364/1). Access to the 3D laser scanner was kindly provided by the HV-Command EPSRC Strategic Equipment Grant (EP/T006420/1), UK.

Funders	Funder number
Future Electrical Machines Manufacturing Hub	EP/P006701/1
Wellcome EPSRC Centre for Medical Engineering	EP/S023364/1, EP/T006420/1

Keywords

A. Laminates
B. Defects
C. Analytical modelling
E. Forming

ASJC Scopus subject areas

Mechanics of Materials
Ceramics and Composites

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Cite this

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An Analytical Model for Wrinkle-free Forming of Composite Laminates

Abstract

Data Availability Statement

Acknowledgements

Funding

Keywords

ASJC Scopus subject areas

Access to Document

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Cite this