Simulation of the thermostamping of woven composites: mesoscopic modelling using explicit fea codes

A hybrid finite element discrete mesoscopic approach is proposed to model the forming of woven-fabric reinforced composites. The yarns are modelled by 1-D elements, and the shearing behaviour of the fabric is incorporated within 2-D elements. The approach has the advantage of being easy to code into a commercial finite element package through a user-defined material subroutine. The material constants can be determined from conventional tensile and shear-frame tests. The proposed material model has been implemented in the ABAQUS and LS-DYNA explicit finite element programs with the material parameters for a Twintex® plain-weave fabric (commingled polypropylene and glass fibres). To validate the approach, shear-frame and bias-extension tests have been modelled, and the finite element results are compared to experimental data. Then, as an example of the capabilities of the method, the thermostamping of a hemisphere has been modelled. The finite element results from ABAQUS and LS-DYNA are similar and agree well when compared to the experimental data.