1 / 19

Collaborative Research:

Collaborative Research:. Enhancing the Understanding of the Fundamental Mechanisms of Thermostamping Woven Composites to Develop a Comprehensive Design Tool. James Sherwood Jennifer Gorczyca University of Massachusetts Lowell Collaborators: Northwestern University. NSF/DOE/APC Workshop:

faunus
Download Presentation

Collaborative Research:

An Image/Link below is provided (as is) to download presentation Download Policy: Content on the Website is provided to you AS IS for your information and personal use and may not be sold / licensed / shared on other websites without getting consent from its author. Content is provided to you AS IS for your information and personal use only. Download presentation by click this link. While downloading, if for some reason you are not able to download a presentation, the publisher may have deleted the file from their server. During download, if you can't get a presentation, the file might be deleted by the publisher.

E N D

Presentation Transcript


  1. Collaborative Research: Enhancing the Understanding of the Fundamental Mechanisms of Thermostamping Woven Composites to Develop a Comprehensive Design Tool James Sherwood Jennifer Gorczyca University of Massachusetts Lowell Collaborators: Northwestern University NSF/DOE/APC Workshop: Future of Modeling in Composites Molding Processes (Design & Optimization Session) 9-10June 2004 Arlington, Virginia NSF Grant Number: DMI- 0331267

  2. Motivation • Mass production of lightweight low-cost woven-fabric reinforced composite parts • Desirable in automobiles for: • High strength-to-weight ratio (compared to metal counterparts) • Reduce weight  Increase fuel efficiency • Development of predictive design tool

  3. Motivation – Thermostamping Punch Binder Ring Fabric Die

  4. Motivation – Part Quality [Wilks, 1999]

  5. Our Research: • Development of a friction model to capture the behavior of balanced plain-weave composite materials during thermoforming • Incorporation of the friction model into the commercial finite element code ABAQUS • Parametric study of the effect of processing parameters on the reaction force on the punch • Use of the fabric friction model with a fabric constitutive model in a commercial finite element code such as ABAQUS to create a predictive tool

  6. ACMTRL Our Research:

  7. Our Research: H Hersey Number h  use Power Law viscosity model U fabric velocity W normal force

  8. State of the Art – Testing Standards • Study of metal/fabric interface relatively new • ASTM standards exist to determine friction coefficients of sheets • Account for normal load and pull-out velocity • Do not account for sheet viscosity and fiber orientation • Researchers have developed their own test methods (many based on ASTM Standard D 1894)

  9. ACMTRL State of the Art – Friction Testing Table from: Gorczyca, Sherwood and Chen (2004). Modeling of Friction and Shear in Thermostamping of Composites – Part I. Journal of Composite Materials. In Press.

  10. ACMTRL State of the Art – FEM • Boisse et al. (1996, 2001a, 2001b) • Constitutive model with FEM focuses on formability • Based on Kawabata et al. (1973) • Xue et al. (2003) and Peng (2003) • Focus on constitutive model and incorporation into FEM • Use of shell elements and nonorthogonality Details can be found in: Gorczyca (2004). A study of the frictional behavior of a plain-weave fabric during the thermostamping process. Doctoral dissertation. Mechanical Engineering Dept. UML

  11. ACMTRL State of the Art – FEM • Cherouat and Billoët (2001) • Truss elements – tows • Membrane elements – resin • Sidhu et al. (2001) • Truss elements – tows • Shell elements – inter-tow friction and fiber angle jamming • Li et al. (2004) [@ UML] • Truss elements – tows • Shell elements – increasing tangent shear modulus Fabric unit cell Truss Elements Shell Element Details can be found in: Gorczyca (2004). A study of the frictional behavior of a plain-weave fabric during the thermostamping process. Doctoral dissertation. Mechanical Engineering Dept. UML

  12. State of the Art – FEM • Reaction force comparison between fabric friction model and Coulomb friction model • Fabric friction model, m=f(H) • Coulomb friction model, m=0.3 Details can be found in: Gorczyca (2004). A study of the frictional behavior of a plain-weave fabric during the thermostamping process. Doctoral dissertation. Mechanical Engineering Dept. UML

  13. Vision • Ability to compare results from different testing methods is important (i.e. shear frame and bias extension, and friction) • Researchers must combine finite element modeling and testing efforts to create a robust Design Tool for thermoforming of woven-fabric composite materials • Analytical Design Tool will account for changing: • Constitutive properties • Temperature • Friction properties • Material types and weaves

  14. Vision • Continue to collaborate with industry to: • Ensure that the appropriate materials and processing techniques are being investigated • Aid technology transfer from academia to industry

  15. Perceived Gaps • Researchers have determined modeling techniques for specific materials, weave types and cases • These methods need to be extended to include “generic” materials, weave types and cases

  16. Perceived Gaps • Researchers have developed their own testing methods (true for constitutive property research and friction modeling) • Work with ASTM for standardized test protocols • Analytical methods for comparing test data using different test procedures must be proposed, publicized and peer-reviewed

  17. Research Thrusts • Collaborative research among modeling laboratories: • Comparison and interpretation of differences in results among different modeling techniques • Joining of different fabric models, such as friction and constitutive, in model of forming processes and interpretation and publication of results • Use these methods to lead to models for “generic” materials, weaves and cases

  18. Research Thrusts • Collaborative research among testing laboratories: • Comparison and interpretation of differences in results using different test procedures • Use these comparisons to work towards standardization of tests and to determine strengths and weaknesses of the different tests that are available

  19. Collaborative Research: Enhancing the Understanding of the Fundamental Mechanisms of Thermostamping Woven Composites to Develop a Comprehensive Design Tool James Sherwood Jennifer Gorczyca University of Massachusetts Lowell Collaborators: Northwestern University NSF/DOE/APC Workshop: Future of Modeling in Composites Molding Processes (Design & Optimization Session) 9-10June 2004 Arlington, Virginia NSF Grant Number: DMI- 0331267

More Related