Modelling and Simulating the Forming of New Dry Automated Lay-up Reinforcements for Primary Structures - Archive ouverte HAL
Communication Dans Un Congrès Année : 2017

Modelling and Simulating the Forming of New Dry Automated Lay-up Reinforcements for Primary Structures

Résumé

While weight has been so far the main driver for the development of prepreg based-composites solutions for aeronautics, a new weight-cost trade-off tends to drive choices for next-generation aircrafts. As a response, Hexcel has designed a new dry reinforcement type for aircraft primary structures, which combines the benefits of automation, out-of-autoclave process cost-effectiveness, and mechanical performances competitive to prepreg solutions: HiTape (R) is a unidirectional (UD) dry carbon reinforcement with thermoplastic veil on each side designed for aircraft primary structures [1-3]. One privileged process route for HiTape (R) in high volume automated processes consists in forming initially flat dry reinforcement stacks, before resin infusion [4] or injection. Simulation of the forming step aims at predicting the geometry and mechanical properties of the formed stack (so-called preform) for process optimisation. Extensive work has been carried out on prepreg and dry woven fabrics forming behaviour and simulation, but the interest for dry non-woven reinforcements has emerged more recently. Some work has been achieved on non crimp fabrics but studies on the forming behaviour of UDs are seldom and deal with UD prepregs only. Tension and bending in the fibre direction, along with inter-ply friction have been identified as the main mechanisms controlling the HiTape (R) response during forming. Bending has been characterised using a modified Peirce's flexometer [5] and inter-ply friction study is under development. Anisotropic hyperelastic constitutive models have been selected to represent the assumed decoupled deformation mechanisms. Model parameters are then identified from associated experimental results. For forming simulation, a continuous approach at the macroscopic scale has been selected first, and simulation is carried out in the Zset framework [6] using proper shell finite elements.
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Dates et versions

hal-04670982 , version 1 (13-08-2024)

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Laure Bouquerel, Nicolas Moulin, Sylvain Drapier, Philippe Boisse, Jean-Marc Beraud. Modelling and Simulating the Forming of New Dry Automated Lay-up Reinforcements for Primary Structures. PROCEEDINGS OF THE 20TH INTERNATIONAL ESAFORM CONFERENCE ON MATERIAL FORMING (ESAFORM 2017), Apr 2017, 2 HUNTINGTON QUADRANGLE, STE 1NO1, MELVILLE, NY 11747-4501 USA, Unknown Region. ⟨10.1063/1.5007995⟩. ⟨hal-04670982⟩
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