A Contribution on Manufacturing Process Development for Composite Material Forming

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The author presents an approach to study an innovative manufacturing process developed to produce composite parts with new geometrical possibilities. The aim of this first study is to understand the motions of fibers during the forming of this kind of composite parts and to explore the feasibility of this forming process by an experimental analysis and FEM simulations with Forge3©. The reliability of the simulation tool and its potential, never exploited in this area, will be evaluated.

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Key Engineering Materials (Volumes 651-653)

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433-438

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July 2015

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© 2015 Trans Tech Publications Ltd. All Rights Reserved

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[8] compared to the hydrostatical pressure founded by the simulations. We defined how to input a coupling between the viscosity and the fiber volume ratio and implement it in a simulation tool by a simple algorithm. The initial part has different area, with different fiber ratio. These fibers ratios induce behavior law on a local area. Coupled to boundary conditions, through an increment of time, the simulation tool calculates the pressure field, and then the displacements of the fibers. The fibers volume ratio is recalculated and the coupling starts again. Figure 5 : Evolution of volumic fiber ratio 5. Conclusions & Outlooks An initial step was realized to identify: - The influence of the process operating parameters, like the viscosity and the temperature. - A link between the fibers impregnation and the pressure field history induced by the forming. The observation of the cut part shows that the fibers impregnation and their placement are dependent on the hydrostatic pressure induced by the tool, and by the processing parameters. As outlooks, a model which is coupling a Carreau-Yasuda/Arrhenius behavior to a mechanical continuous element with the properties of carbon fibers will be confronted to a real part. This comparison will validate the link between the void content, the displacement of the fibers, the fiber volume ratio and the pressure field history of the part. The aim is to quantify the link observed between the displacement of the fibers and the pressure fields induced by the process, and characterize the potential of it with different materials, at different processing settings. In order to master all the forming operations, the cartography of the pressure field's history obtained in the simulations will be used. Bibliography.

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