Forming of Hybrid (CF UD Prepreg - Advanced SMC) Composite Layups
Source abstract
Abstract
Abstract Combining continuous unidirectional (UD) prepreg and advanced discontinuous long fiber-based sheet moulding compound (ASMC) in a hybrid component is advantageous for applications where cost and environmental impact of the manufactured part are of significance. Previous works have focused on the flow/compaction of ASMC and its interaction with continuous fibres at high pressures. However, little is known about the forming behaviour of such layups. This work investigates the formability of hybrid carbon fibre UD-ASMC composite layups. The deformation mechanisms during forming and their interactions are investigated experimentally. Forming simulations are conducted alongside experimental tests under varying layup configurations. The results show that the hybrid layup combinations investigated exhibited poor forming characteristics. This was due to the high interply friction properties of the UD-ASMC interface, which, in turn, restricted the intraply shear of the hybrid stack. A strong correlation between the numerically predicted forming outcomes and experimentally formed parts demonstrates that generic FE-solvers can provide a first estimate of the forming outcome when coupled with a good understanding of the underlying deformation mechanisms. However, these methods are computationally expensive and are better suited for detailed evaluations rather than for use in design applications.
Source: crossref · Quality: baseline
Research context
OpenAlex topics: Additive Manufacturing and 3D Printing Technologies · Mechanical Behavior of Composites · Innovations in Concrete and Construction Materials
SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.
References (58)
Show source-provided references
1. Meng, F., McKechnie, J., Pickering, S.J.: An assessment of financial viability of recycled carbon fibre in automotive applications. Compos. A Appl. Sci. Manuf. 109, 207–220 (2018). https://doi.org/10.1016/j.compositesa.2018.03.01110.1016/j.compositesa.2018.03.011 ↗
2. Wulfsberg, J., Herrmann, A., Ziegmann, G., Lonsdorfer, G., Stöß, N., Fette, M.: Combination of carbon fibre sheet moulding compound and prepreg compression moulding in aerospace industry. Procedia Engineering. 81, 1601–1607 (2014). https://doi.org/10.1016/j.proeng.2014.10.197. 11th International Conference on Technology of Plasticity, ICTP 2014, 19-24 October 2014, Nagoya Congress Center, Nagoya, Japan10.1016/j.proeng.2014.10.197 ↗
3. Visweswaraiah, S.B., Lessard, L., Hubert, P.: Tensile behaviour of hybrid fibre architectures of randomly oriented strands combined with laminate groups. J. Compos. Mater. 53(26–27), 3725–3740 (2019). https://doi.org/10.1177/002199831984459010.1177/0021998319844590 ↗
4. Selmy, A.I., Elsesi, A.R., Azab, N.A., Abd El-baky, M.A.: Interlaminar shear behavior of unidirectional glass fiber (u)/random glass fiber (r)/epoxy hybrid and non-hybrid composite laminates. Compos. B Eng. 43(4), 1714–1719 (2012). https://doi.org/10.1016/j.compositesb.2012.01.03110.1016/j.compositesb.2012.01.031 ↗
5. Pheysey, J., De Cola, F., Martinez-Hergueta, F.: Short fibre/unidirectional hybrid thermoplastic composites: Experimental characterisation and digital analysis. Composites Part A: Applied Science and Manufacturing. 181, 108121 (2024). https://doi.org/10.1016/j.compositesa.2024.10812110.1016/j.compositesa.2024.108121 ↗
6. Hagnell, M.K., Åkermo, M.: The economic and mechanical potential of closed loop material usage and recycling of fibre-reinforced composite materials. J. Clean. Prod. 223, 957–968 (2019). https://doi.org/10.1016/j.jclepro.2019.03.15610.1016/j.jclepro.2019.03.156 ↗
7. Meng, F., Cui, Y., Pickering, S., McKechnie, J.: From aviation to aviation: Environmental and financial viability of closed-loop recycling of carbon fibre composite. Compos. B Eng. 200, 108362 (2020). https://doi.org/10.1016/j.compositesb.2020.10836210.1016/j.compositesb.2020.108362 ↗
8. Nakagawa, T., Ko, S., Houser, G., Yang, J., Salviato, M.: Repurposed discontinuous fiber composites for industrial applications: Effects of average number of platelets through the thickness, platelet length, and hybridization on flexure properties. Composites Part A: Applied Science and Manufacturing. 180, 108046 (2024) https://doi.org/10.1016/j.compositesa.2024.10804610.1016/j.compositesa.2024.108046 ↗
9. Stelzer, P.S., Cakmak, U., Eisner, L., Doppelbauer, L.K., Kállai, I., Schweizer, G., Prammer, H.K., Major, Z.: Experimental feasibility and environmental impacts of compression molded discontinuous carbon fiber composites with opportunities for circular economy. Compos. B Eng. 234, 109638 (2022). https://doi.org/10.1016/j.compositesb.2022.10963810.1016/j.compositesb.2022.109638 ↗
10. Iyer, K., Hagnell, M.K., Åkermo, M.: The multi-objective optimization framework: A step towards minimizing life-cycle costs and energy consumption of carbon fibre automotive structures. Compos. B Eng. 271, 111158 (2024). https://doi.org/10.1016/j.compositesb.2023.11115810.1016/j.compositesb.2023.111158 ↗
11. McConnell, V.P.: New recipes for smc innovation. Reinf. Plast. 52(8), 34–39 (2008). https://doi.org/10.1016/S0034-3617(08)70309-610.1016/S0034-3617(08)70309-6 ↗
12. Corbridge, D.M., Harper, L.T., De Focatiis, D.S.A., Warrior, N.A.: Compression moulding of composites with hybrid fibre architectures. Compos. A Appl. Sci. Manuf. 95, 87–99 (2017). https://doi.org/10.1016/j.compositesa.2016.12.01810.1016/j.compositesa.2016.12.018 ↗
13. Dumont, P., Le Corre, S., Orgéas, L., Favier, D., Gaborit, C., Lory, P.: Finite element implementation of a two-phase model for compression molding of composites. Revue Europeenne des Elements. 14(6–7), 885–902 (2005). https://doi.org/10.3166/reef.14.885-90210.3166/reef.14.885-902 ↗
14. Aitomäki, Y., Berglund, D.: Carbon and glass smc hybrids in a sandwich arrangement. In: Proceedings of the 20th European Conference on Composite Materials, Lausanne, Switzerland (2022). ECMC20
15. Gupta, J., Reynolds, N., Chiciudean, T., Kendall, K.: A comparative study between epoxy and vinyl ester cf-smc for high volume automotive composite crash structures. Compos. Struct. 244, 112299 (2020). https://doi.org/10.1016/j.compstruct.2020.11229910.1016/j.compstruct.2020.112299 ↗
16. Yuan, H., Khan, M., Peijs, T., Qian, C.: Experimental process characterisation for high-volume compression moulding of hybrid-architecture composites. Composites Part A: Applied Science and Manufacturing. 181, 108137 (2024) https://doi.org/10.1016/j.compositesa.2024.10813710.1016/j.compositesa.2024.108137 ↗
17. Mallick, P.K.: Effect of fiber misorientation on the tensile strength of compression molded continuous fiber composites. Polym. Compos. 7(1), 14–18 (1986). https://doi.org/10.1002/pc.75007010410.1002/pc.750070104 ↗
18. Larberg, Y.: Forming of stacked unidirectional prepreg materials. PhD thesis, KTH Royal Institute of Technology (2012). https://urn.kb.se/resolve?urn=urn:nbn:se:kth:diva-106269
19. Hallander, P., Sjölander, J., Åkermo, M.: Forming induced wrinkling of composite laminates with mixed ply material properties; an experimental study. Compos. A Appl. Sci. Manuf. 78, 234–245 (2015). https://doi.org/10.1016/j.compositesa.2015.08.02510.1016/j.compositesa.2015.08.025 ↗
20. Sjölander, J., Hallander, P., Åkermo, M.: Forming induced wrinkling of composite laminates: A numerical study on wrinkling mechanisms. Compos. A Appl. Sci. Manuf. 81, 41–51 (2016). https://doi.org/10.1016/j.compositesa.2015.10.01210.1016/j.compositesa.2015.10.012 ↗
21. Hallander, P., Sjölander, J., Petersson, M., Åkermo, M.: Interface manipulation towards wrinkle-free forming of stacked ud prepreg layers. Compos. A Appl. Sci. Manuf. 90, 340–348 (2016). https://doi.org/10.1016/j.compositesa.2016.07.01310.1016/j.compositesa.2016.07.013 ↗
22. Johnson, K.J., Butler, R., Loukaides, E.G., Scarth, C., Rhead, A.T.: Stacking sequence selection for defect-free forming of uni-directional ply laminates. Compos. Sci. Technol. 171, 34–43 (2019). https://doi.org/10.1016/j.compscitech.2018.11.04810.1016/j.compscitech.2018.11.048 ↗
23. Trenam, A., Aza, C., Jones, C., Lawrence, G., Harper, L., Rhead, A., Loukaides, E.G., Butler, R.: An analytical model for wrinkle-free forming of composite laminates. Composites Part A: Applied Science and Manufacturing. 186, 108386 (2024). https://doi.org/10.1016/j.compositesa.2024.10838610.1016/j.compositesa.2024.108386 ↗
24. Alshahrani, H., Hojjati, M.: Experimental and numerical investigations on formability of out-of-autoclave thermoset prepreg using a double diaphragm process. Compos. A Appl. Sci. Manuf. 101, 199–214 (2017). https://doi.org/10.1016/j.compositesa.2017.06.02110.1016/j.compositesa.2017.06.021 ↗
25. Hallander, P., Akermo, M., Mattei, C., Petersson, M., Nyman, T.: An experimental study of mechanisms behind wrinkle development during forming of composite laminates. Compos. A Appl. Sci. Manuf. 50, 54–64 (2013). https://doi.org/10.1016/j.compositesa.2013.03.01310.1016/j.compositesa.2013.03.013 ↗
26. Haanappel, S.P., ten Thije, R.H.W., Sachs, U., Rietman, B., Akkerman, R.: Formability analyses of uni-directional and textile reinforced thermoplastics. Compos. A Appl. Sci. Manuf. 56, 80–92 (2014). https://doi.org/10.1016/j.compositesa.2013.09.00910.1016/j.compositesa.2013.09.009 ↗
27. Long, A.C., Clifford, M.J.: 1 - composite forming mechanisms and materials characterisation. In: Long, A.C. (ed.) Composites Forming Technologies. Woodhead Publishing Series in Textiles, pp. 1–21. Woodhead Publishing (2007). https://doi.org/10.1533/9781845692537.110.1533/9781845692537.1 ↗
28. Potter, K.: Bias extension measurements on cross-plied unidirectional prepreg. Compos. A Appl. Sci. Manuf. 33(1), 63–73 (2002). https://doi.org/10.1016/S1359-835X(01)00057-410.1016/S1359-835X(01)00057-4 ↗
29. Larberg, Y.R., Åkermo, M., Norrby, M.: On the in-plane deformability of cross-plied unidirectional prepreg. J. Compos. Mater. 46(8), 929–939 (2012). https://doi.org/10.1177/002199831141298810.1177/0021998311412988 ↗
30. Liang, B., Hamila, N., Peillon, M., Boisse, P.: Analysis of thermoplastic prepreg bending stiffness during manufacturing and of its influence on wrinkling simulations. Compos. A Appl. Sci. Manuf. 67, 111–122 (2014). https://doi.org/10.1016/j.compositesa.2014.08.02010.1016/j.compositesa.2014.08.020 ↗
31. Boisse, P., Hamila, N., Vidal-Sallé, E., Dumont, F.: Simulation of wrinkling during textile composite reinforcement forming. influence of tensile, in-plane shear and bending stiffnesses. Composites Science and Technology. 71(5), 683–692 (2011) https://doi.org/10.1016/j.compscitech.2011.01.01110.1016/j.compscitech.2011.01.011 ↗
32. Larberg, Y.R., Åkermo, M.: On the interply friction of different generations of carbon/epoxy prepreg systems. Compos. A Appl. Sci. Manuf. 42(9), 1067–1074 (2011)10.1016/j.compositesa.2011.04.010 ↗
33. Erland, S., Dodwell, T.J., Butler, R.: Characterisation of inter-ply shear in uncured carbon fibre prepreg. Compos. A Appl. Sci. Manuf. 77, 210–218 (2015). https://doi.org/10.1016/j.compositesa.2015.07.00810.1016/j.compositesa.2015.07.008 ↗
34. Dutta, A., Hagnell, M.K., Åkermo, M.: Interply friction between unidirectional carbon/epoxy prepreg plies: Influence of fibre orientation. Composites Part A: Applied Science and Manufacturing. 166 (2023) https://doi.org/10.1016/j.compositesa.2022.10737510.1016/j.compositesa.2022.107375 ↗
35. Pasco, C., Khan, M., Gupta, J., Kendall, K.: Experimental investigation on interply friction properties of thermoset prepreg systems. J. Compos. Mater. 53(2), 227–243 (2019). https://doi.org/10.1177/002199831878170610.1177/0021998318781706 ↗
36. Rashidi, A., Montazerian, H., Yesilcimen, K., Milani, A.S.: Experimental characterization of the inter-ply shear behavior of dry and prepreg woven fabrics: Significance of mixed lubrication mode during thermoset composites processing. Composites Part A: Applied Science and Manufacturing. 129, 105725 (2020) https://doi.org/10.1016/j.compositesa.2019.10572510.1016/j.compositesa.2019.105725 ↗
37. Bloom, L.D., Wang, J., Potter, K.D.: Damage progression and defect sensitivity: an experimental study of representative wrinkles in tension. Compos. B Eng. 45(1), 449–458 (2013)10.1016/j.compositesb.2012.05.021 ↗
38. Sachs, U., Akkerman, R., Fetfatsidis, K., Vidal-Sallé, E., Schumacher, J., Ziegmann, G., Allaoui, S., Hivet, G., Maron, B., Vanclooster, K., Lomov, S.V.: Characterization of the dynamic friction of woven fabrics: Experimental methods and benchmark results. Compos. A Appl. Sci. Manuf. 67, 289–298 (2014). https://doi.org/10.1016/j.compositesa.2014.08.02610.1016/j.compositesa.2014.08.026 ↗
39. Harrison, P., Clifford, M.J., Long, A.C.: Shear characterisation of viscous woven textile composites: a comparison between picture frame and bias extension experiments. Compos. Sci. Technol. 64(10), 1453–1465 (2004). https://doi.org/10.1016/j.compscitech.2003.10.01510.1016/j.compscitech.2003.10.015 ↗
40. Launay, J., Hivet, G., Duong, A.V., Boisse, P.: Experimental analysis of the influence of tensions on in plane shear behaviour of woven composite reinforcements. Compos. Sci. Technol. 68(2), 506–515 (2008). https://doi.org/10.1016/j.compscitech.2007.06.02110.1016/j.compscitech.2007.06.021 ↗
41. Hallander, P.: Towards defect free forming of multi-stacked composite aerospace components using tailored interlayer properties. PhD thesis, KTH, Lightweight Structures (2016). QC 20160425
42. Sjölander, J.: Improving forming of aerospace composite components through process modelling. PhD thesis, KTH, Lightweight Structures (2018). QC 20180806
43. Han, M.-G., Chang, S.-H.: Draping simulations of carbon/epoxy fabric prepregs using a non-orthogonal constitutive model considering bending behavior. Composites Part A: Applied Science and Manufacturing. 148, 106483 (2021) https://doi.org/10.1016/j.compositesa.2021.10648310.1016/j.compositesa.2021.106483 ↗
44. Standard test method for stiffness of fabrics. (ASTM D1388-18) (2018) https://doi.org/10.1520/D1388-1810.1520/D1388-18 ↗
45. Yu, F., Chen, S., Viisainen, J., Sutcliffe, M., Harper, L., Warrior, N.: A macroscale finite element approach for simulating the bending behaviour of biaxial fabrics. Compos. Sci. Technol. 191, 108078 (2020)10.1016/j.compscitech.2020.108078 ↗
46. ten Thije, R.H.W., Akkerman, R., Huétink, J.: Large deformation simulation of anisotropic material using an updated lagrangian finite element method. Comput. Methods Appl. Mech. Eng. 196(33), 3141–3150 (2007). https://doi.org/10.1016/j.cma.2007.02.01010.1016/j.cma.2007.02.010 ↗
47. Dörr, D., Schirmaier, F.J., Henning, F., Kärger, L.: 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 (2017). https://doi.org/10.1016/j.compositesa.2016.11.02710.1016/j.compositesa.2016.11.027 ↗
48. Gereke, T., Döbrich, O., Hübner, M., Cherif, C.: Experimental and computational composite textile reinforcement forming: A review. Compos. A Appl. Sci. Manuf. 46, 1–10 (2013). https://doi.org/10.1016/j.compositesa.2012.10.00410.1016/j.compositesa.2012.10.004 ↗
49. Dörr, D., Brymerski, W., Ropers, S., Leutz, D., Joppich, T., Kärger, L., Henning, F.: A benchmark study of finite element codes for forming simulation of thermoplastic ud-tapes. Procedia CIRP. 66, 101–106 (2017). https://doi.org/10.1016/j.procir.2017.03.223. 1st CIRP Conference on Composite Materials Parts Manufacturing (CIRP CCMPM 2017)10.1016/j.procir.2017.03.223 ↗
50. Boisse, P., Colmars, J., Hamila, N., Naouar, N., Steer, Q.: Bending and wrinkling of composite fiber preforms and prepregs. a review and new developments in the draping simulations. Composites Part B: Engineering. 141, 234–249 (2018) https://doi.org/10.1016/j.compositesb.2017.12.06110.1016/j.compositesb.2017.12.061 ↗
51. Hamila, N., Boisse, P., Sabourin, F., Brunet, M.: A semi-discrete shell finite element for textile composite reinforcement forming simulation. Int. J. Numer. Meth. Eng. 79(12), 1443–1466 (2009). https://doi.org/10.1002/nme.262510.1002/nme.2625 ↗
52. Döbrich, O., Gereke, T., Diestel, O., Krzywinski, S., Cherif, C.: Decoupling the bending behavior and the membrane properties of finite shell elements for a correct description of the mechanical behavior of textiles with a laminate formulation. J. Ind. Text. 44(1), 70–84 (2014)10.1177/1528083713477442 ↗
53. Nishii, M., Hirashima, T., Kurashiki, T.: Dry fabric forming analysis considering the influence of tensions on in-plane shear behavior. Zairyo/Journal of the Society of Materials Science, Japan. 63(5), 380–385 (2014). https://doi.org/10.2472/jsms.63.38010.2472/jsms.63.380 ↗
54. Thompson, A.J., Belnoue, J.P.-H., Hallett, S.R.: Modelling defect formation in textiles during the double diaphragm forming process. Compos. B Eng. 202, 108357 (2020). https://doi.org/10.1016/j.compositesb.2020.10835710.1016/j.compositesb.2020.108357 ↗
55. Yildirim, H., Ozturk, F.: A benchmark study of the material models for forming simulation of woven fabrics. The Journal of The Textile Institute. 113(6), 1027–1038 (2022). https://doi.org/10.1080/00405000.2021.191440910.1080/00405000.2021.1914409 ↗
56. ANSYS, I.: LS-DYNA R14 Keyword Manual Vol II. https://lsdyna.ansys.com/manuals/
57. ANSYS, I.: LS-DYNA Theory Manual. https://lsdyna.ansys.com/manuals/
58. Rashidi, A., Belnoue, J.P.-H., Thompson, A.J., Hallett, S.R., Milani, A.S.: Consolidation-driven wrinkling in carbon/epoxy woven fabric prepregs: An experimental and numerical study. Composites Part A: Applied Science and Manufacturing. 143, 106298 (2021) https://doi.org/10.1016/j.compositesa.2021.10629810.1016/j.compositesa.2021.106298 ↗