UNIMAT: An enhanced forming simulation model of prepreg woven fabrics, with application to process optimization for wrinkle mitigation

1. Bloom LD, Wang J, Potter KD (2013) Damage progression and defect sensitivity: An experimental study of representative wrinkles in tension. Compos B Eng 45:449–458. https://doi.org/10.1016/j.compositesb.2012.05.02110.1016/j.compositesb.2012.05.021 ↗

2. Hallander P, Sjölander J, Åkermo M (2015) Forming induced wrinkling of composite laminates with mixed ply material properties; an experimental study. Compos A Appl Sci Manuf 78:234–245. https://doi.org/10.1016/j.compositesa.2015.08.02510.1016/j.compositesa.2015.08.025 ↗

3. Wang D, Naouar N, Vidal-Salle E, Boisse P (2018) Longitudinal compression and Poisson ratio of fiber yarns in meso-scale finite element modeling of composite reinforcements. Compos B Eng 141:9–19. https://doi.org/10.1016/j.compositesb.2017.12.04210.1016/j.compositesb.2017.12.042 ↗

4. Dodwell TJ, Butler R, Hunt GW (2014) Out-of-plane ply wrinkling defects during consolidation over an external radius. Compos Sci Technol 105:151–159. https://doi.org/10.1016/j.compscitech.2014.10.00710.1016/j.compscitech.2014.10.007 ↗

5. Hallander P, Akermo M, Mattei C, Petersson M, Nyman T (2013) An experimental study of mechanisms behind wrinkle development during forming of composite laminates. Compos A Appl Sci Manuf 50:54–64. https://doi.org/10.1016/j.compositesa.2013.03.01310.1016/j.compositesa.2013.03.013 ↗

6. Potter K (2002) Beyond the pin-jointed net: maximising the deformability of aligned continuous fibre reinforcements. Compos A 5:677–68610.1016/S1359-835X(02)00014-3 ↗

7. Potter K, Khan B, Wisnom M, Bell T, Stevens J (2008) Variability, fibre waviness and misalignment in the determination of the properties of composite materials and structures. Compos A Appl Sci Manuf 39:1343–1354. https://doi.org/10.1016/j.compositesa.2008.04.01610.1016/j.compositesa.2008.04.016 ↗

8. de Bilbao E, Soulat D, Hivet G, Gasser A (2010) Experimental Study of Bending Behaviour of Reinforcements. Exp Mech 50:333–351. https://doi.org/10.1007/s11340-009-9234-910.1007/s11340-009-9234-9 ↗

9. Boisse P, Hamila N, Vidal-Sallé E, Dumont F (2011) Simulation of wrinkling during textile composite reinforcement forming. Influence of tensile, in-plane shear and bending stiffnesses. Compos Sci Technol 71:683–692. https://doi.org/10.1016/j.compscitech.2011.01.01110.1016/j.compscitech.2011.01.011 ↗

10. Mathieu S, Hamila N, Bouillon F, Boisse P (2015) Enhanced modeling of 3D composite preform deformations taking into account local fiber bending stiffness. Compos Sci Technol 117:322–333. https://doi.org/10.1016/j.compscitech.2015.07.00510.1016/j.compscitech.2015.07.005 ↗

11. Dangora LM, Mitchell CJ, Sherwood JA (2015) Predictive model for the detection of out-of-plane defects formed during textile-composite manufacture. Compos A Appl Sci Manuf 78:102–112. https://doi.org/10.1016/j.compositesa.2015.07.01110.1016/j.compositesa.2015.07.011 ↗

12. Liang B, Chaudet P, Boisse P (2017) Curvature determination in the bending test of continuous fibre reinforcements. Strain 53:e12213. https://doi.org/10.1111/str.1221310.1111/str.12213 ↗

13. Alshahrani H, Hojjati M (2017) Bending behavior of multilayered textile composite prepregs: Experiment and finite element modeling. Mater Des 124:211–224. https://doi.org/10.1016/j.matdes.2017.03.07710.1016/j.matdes.2017.03.077 ↗

14. Boisse P, Colmars J, Hamila N, Naouar N, Steer Q (2018) Bending and wrinkling of composite fiber preforms and prepregs. A review and new developments in the draping simulations. Compos Part B: Eng 141:234–249. https://doi.org/10.1016/j.compositesb.2017.12.06110.1016/j.compositesb.2017.12.061 ↗

15. Ghafour TA, Colmars J, Boisse P (2019) The importance of taking into account behavior irreversibilities when simulating the forming of textile composite reinforcements. Compos - A: Appl Sci Manuf 127:105641. https://doi.org/10.1016/j.compositesa.2019.10564110.1016/j.compositesa.2019.105641 ↗

16. Nosrat-Nezami F, Gereke T, Eberdt C, Cherif C (2014) Characterisation of the shear–tension coupling of carbon-fibre fabric under controlled membrane tensions for precise simulative predictions of industrial preforming processes. Compos A Appl Sci Manuf 67:131–139. https://doi.org/10.1016/j.compositesa.2014.08.03010.1016/j.compositesa.2014.08.030 ↗

17. Chen S, Harper LT, Endruweit A, Warrior NA (2015) Formability optimisation of fabric preforms by controlling material draw-in through in-plane constraints. Compos A Appl Sci Manuf 76:10–19. https://doi.org/10.1016/j.compositesa.2015.05.00610.1016/j.compositesa.2015.05.006 ↗

18. Kärger L, Galkin S, Zimmerling C et al (2018) Forming optimisation embedded in a CAE chain to assess and enhance the structural performance of composite components. Compos Struct 192:143–15210.1016/j.compstruct.2018.02.041 ↗

19. Allaoui S, Boisse P, Chatel S, Hamila N, Hivet G, Soulat D, Vidal-Salle E (2011) Experimental and numerical analyses of textile reinforcement forming of a tetrahedral shape. Compos A Appl Sci Manuf 42:612–622. https://doi.org/10.1016/j.compositesa.2011.02.00110.1016/j.compositesa.2011.02.001 ↗

20. Boisse P, Zouari B, Daniel J-L (2006) Importance of in-plane shear rigidity in finite element analyses of woven fabric composite preforming. Compos A Appl Sci Manuf 37:2201–2212. https://doi.org/10.1016/j.compositesa.2005.09.01810.1016/j.compositesa.2005.09.018 ↗

21. Cherouat A, Borouchaki H, Giraud-Moreau L (2010) Mechanical and geometrical approaches applied to composite fabric forming. Int J Mater Form 3:1189–1204. https://doi.org/10.1007/s12289-010-0692-510.1007/s12289-010-0692-5 ↗

22. Chen S, McGregor OPL, Harper LT, Endruweit A, Warrior NA (2016) Defect formation during preforming of a bi-axial non-crimp fabric with a pillar stitch pattern. Compos A Appl Sci Manuf 91:156–167. https://doi.org/10.1016/j.compositesa.2016.09.01610.1016/j.compositesa.2016.09.016 ↗

23. Chen S, McGregor OPL, Endruweit A, Elsmore MT, De Focatiis DSA, Harper LT, Warrior NA (2017) Double diaphragm forming simulation for complex composite structures. Compos A Appl Sci Manuf 95:346–358. https://doi.org/10.1016/j.compositesa.2017.01.01710.1016/j.compositesa.2017.01.017 ↗

24. Liang B, Zhang W, Fenner JS, Gao J, Shi Y, Zeng D, Su X, Liu WK, Cao J (2019) Multi-scale modeling of mechanical behavior of cured woven textile composites accounting for the influence of yarn angle variation. Compos A Appl Sci Manuf 124:105460. https://doi.org/10.1016/j.compositesa.2019.05.02810.1016/j.compositesa.2019.05.028 ↗

25. Hamila N, Boisse P, Sabourin F, Brunet M (2009) A semi-discrete shell finite element for textile composite reinforcement forming simulation. Int J Numer Meth Eng 79:1443–1466. https://doi.org/10.1002/nme.262510.1002/nme.2625 ↗

26. Thompson AJ, Belnoue JP-H, Hallett SR (2020) Modelling defect formation in textiles during the double diaphragm forming process. Compos B Eng 202:108357. https://doi.org/10.1016/j.compositesb.2020.10835710.1016/j.compositesb.2020.108357 ↗

27. Sourki R, Crawford B, Vaziri R, Milani AS (2022) Meso-level bending/reverse-bending analysis of dry woven fabrics: Observing an irreversible behavior during forming. Compos Struct 282:115124. https://doi.org/10.1016/j.compstruct.2021.11512410.1016/j.compstruct.2021.115124 ↗

28. Guzman-Maldonado E, Hamila N, Naouar N, Moulin G, Boisse P (2016) Simulation of thermoplastic prepreg thermoforming based on a visco-hyperelastic model and a thermal homogenization. Mater Des 93:431–442. https://doi.org/10.1016/j.matdes.2015.12.16610.1016/j.matdes.2015.12.166 ↗

29. Dörr D, Schirmaier FJ, Henning F, Kärger L (2017) A viscoelastic approach for modeling bending behavior in finite element forming simulation of continuously fiber reinforced composites. Compos A Appl Sci Manuf 94:113–123. https://doi.org/10.1016/j.compositesa.2016.11.02710.1016/j.compositesa.2016.11.027 ↗

30. Denis Y, Morestin F, Hamila N (2020) A hysteretic model for fiber-reinforced composites at finite strains: fractional derivatives, computational aspects and analysis. Comput Mater Sci 181:109716. https://doi.org/10.1016/j.commatsci.2020.10971610.1016/j.commatsci.2020.109716 ↗

31. Sourki R, Milani AS, Vaziri R (2019) Towards understanding and modeling irreversible behavior of woven fabrics under loading-unloading bending regimes, in: 22nd International Conference on Composites Materials (ICCM22), Engineers Australia, Melbourne, VIC, pp. 4225–4231. https://doi.org/10.3316/informit.89422062800320110.3316/informit.894220628003201 ↗

32. Kawabata S, The standardization and analysis of hand evaluation, in: Effect of Mechanical and Physical Properties on Fabric Hand, Woodhead Publishing, 2005: pp. 389–44210.1533/9781845690984.appendix_a ↗

33. Faal RT, Sourki R, Crawford B, Vaziri R, Milani AS (2020) Using fractional derivatives for improved viscoelastic modeling of textile composites Part I: Fabric yarns. J Compos Mater 54:3245–3260. https://doi.org/10.1177/002199832091247910.1177/0021998320912479 ↗

34. Faal RT, Sourki R, Crawford B, Vaziri R, Milani AS (2020) Using fractional derivatives for improved viscoelastic modeling of textile composites Part II: Fabric under different temperatures. Compos Struct 248:112494. https://doi.org/10.1016/j.compstruct.2020.11249410.1016/j.compstruct.2020.112494 ↗

35. Cao J, Akkerman R, Boisse P, Chen J, Cheng HS, de Graaf EF, Gorczyca JL, Harrison P, Hivet G, Launay J, Lee W, Liu L, Lomov SV, Long A, de Luycker E, Morestin F, Padvoiskis J, Peng XQ, Sherwood J, Stoilova TZ, Tao XM, Verpoest I, Willems A, Wiggers J, Yu TX, Zhu B (2008) Characterization of mechanical behavior of woven fabrics: Experimental methods and benchmark results. Compos - A: Appl Sci Manuf 39:1037–1053. https://doi.org/10.1016/j.compositesa.2008.02.01610.1016/j.compositesa.2008.02.016 ↗

36. Sourki R, Crawford B, Vaziri R, Milani AS (2021) Orientation Dependency and Hysteresis Nature of Inter-Ply Friction in Woven Fabrics. Appl Compos Mater 28:113–127. https://doi.org/10.1007/s10443-020-09846-y10.1007/s10443-020-09846-y ↗

37. Peirce FT (1930) 26—the “Handle” of Cloth as a Measurable Quantity. J Text Inst Transact 21:T377–T416. https://doi.org/10.1080/1944702300866152910.1080/19447023008661529 ↗

38. Sachs U, Akkerman R, Fetfatsidis K, Vidal-Sallé E, Schumacher J, Ziegmann G, Allaoui S, Hivet G, Maron B, Vanclooster K, Lomov SV (2014) Characterization of the dynamic friction of woven fabrics: Experimental methods and benchmark results. Compos A Appl Sci Manuf 67:289–298. https://doi.org/10.1016/j.compositesa.2014.08.02610.1016/j.compositesa.2014.08.026 ↗

39. Mosaferi Y, Crawford B, Torres J, Milani AS (2017) On static and dynamic friction characterization of tool-fiber interaction: Effect of mould type and processing conditions. MOJ Polymer Sci 1(2):1–7

40. Sourki R (2021) Forming simulation of prepreg plain weave fabrics, University of British Columbia. https://doi.org/10.14288/1.040248610.14288/1.0402486 ↗

41. Akiba T, Sano S, Yanase T, Ohta T, Koyama M (2019) Optuna: A Next-generation Hyperparameter Optimization Framework, arXiv:1907.10902 [Cs, Stat]. http://arxiv.org/abs/1907.10902 (accessed January 2, 2022)

42. Hansen N (2016) The CMA Evolution Strategy: A Tutorial, arXiv:1604.00772 [Cs, Stat]. http://arxiv.org/abs/1604.00772 (accessed January 2, 2022)

43. Crawford B, Sourki R, Khayyam H, Milani AS (2021) A machine learning framework with dataset-knowledgeability pre-assessment and a local decision-boundary crispness score: An industry 4.0-based case study on composite autoclave manufacturing. Comput Ind 132:103510. https://doi.org/10.1016/j.compind.2021.10351010.1016/j.compind.2021.103510 ↗

44. Chen S, Endruweit A, Harper LT, Warrior NA (2014) Forming simulations of multi-layered woven preforms assembled with stitch yarns, in: ECCM16—16th European Conference On Composite Materials, Seville, Spain, pp. 22–26

45. Lee JS, Hong SJ, Yu W-R, Kang TJ (2007) The effect of blank holder force on the stamp forming behavior of non-crimp fabric with a chain stitch. Compos Sci Technol 67:357–366. https://doi.org/10.1016/j.compscitech.2006.09.00910.1016/j.compscitech.2006.09.009 ↗

46. Lin H, Wang J, Long AC, Clifford MJ, Harrison P (2007) Predictive modelling for optimization of textile composite forming. Compos Sci Technol 67:3242–3252. https://doi.org/10.1016/j.compscitech.2007.03.04010.1016/j.compscitech.2007.03.040 ↗

47. Haanappel SP, ten Thije RHW, Sachs U, Rietman B, Akkerman R (2014) Formability analyses of uni-directional and textile reinforced thermoplastics. Compos A Appl Sci Manuf 56:80–92. https://doi.org/10.1016/j.compositesa.2013.09.00910.1016/j.compositesa.2013.09.009 ↗

48. Chen A, McGregor OPL, Harper LT, Endruweit A, Warrior NA (2018) Optimisation of local in-plane constraining forces in double diaphragm forming. Compos Struct 201. https://doi.org/10.1016/j.compstruct.2018.06.062.10.1016/j.compstruct.2018.06.062 ↗

49. Sourki R, Faal RT, Milani AS (2020) Vibration Analysis of Orthotropic Functionally Graded Composite Plates in Thermal Environment Using High-Order Shear Deformation Theory: Frequency Suppression by Tuning the In-Plane Forces. Int J Appl Comput Math 6:59. https://doi.org/10.1007/s40819-020-00806-510.1007/s40819-020-00806-5 ↗

50. Peng XQ, Cao J (2005) A continuum mechanics-based non-orthogonal constitutive model for woven composite fabrics. Compos A Appl Sci Manuf 36:859–874. https://doi.org/10.1016/j.compositesa.2004.08.00810.1016/j.compositesa.2004.08.008 ↗

51. Lightfoot JS, Wisnom MR, Potter K (2013) A new mechanism for the formation of ply wrinkles due to shear between plies. Compos A Appl Sci Manuf 49:139–147. https://doi.org/10.1016/j.compositesa.2013.03.00210.1016/j.compositesa.2013.03.002 ↗

52. Yu F, Chen S, Viisainen JV, Sutcliffe MPF, Harper LT, Warrior NA (2020) A macroscale finite element approach for simulating the bending behaviour of biaxial fabrics. Compos Sci Technol 191:108078. https://doi.org/10.1016/j.compscitech.2020.10807810.1016/j.compscitech.2020.108078 ↗

53. Chen S, Endruweit A, Harper LT, Warrior NA (2015) Inter-ply stitching optimisation of highly drapeable multi-ply preforms. Compos A Appl Sci Manuf 71:144–156. https://doi.org/10.1016/j.compositesa.2015.01.01610.1016/j.compositesa.2015.01.016 ↗

54. Kashani MH, Hosseini A, Saassani F, Ko KF, Milani AS (2017) Understanding different types of coupling in mechanical behaviour of woven fabric reinforcements: a critical review and analysis”. Compos Struct 179. https://doi.org/10.1016/j.compstruct.2017.06.06910.1016/j.compstruct.2017.06.069 ↗