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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: - PowerPoint PPT Presentation

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  • Collaborative Research: James SherwoodJennifer Gorczyca University of Massachusetts Lowell

    Collaborators: Northwestern University

    Enhancing the Understanding of the Fundamental Mechanisms of Thermostamping Woven Composites to Develop a Comprehensive Design ToolNSF Grant Number: DMI- 0331267NSF/DOE/APC Workshop: Future of Modeling in Composites Molding Processes (Design & Optimization Session)9-10 June 2004Arlington, Virginia

  • MotivationMass 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

  • Motivation ThermostampingPunchBinder RingFabricDie

  • Motivation Part Quality[Wilks, 1999]

  • 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

  • ACMTRLOur Research:

  • Our Research:H Hersey Numberh use Power Law viscosity modelU fabric velocityW normal force

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

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

  • State of the Art FEMBoisse et al. (1996, 2001a, 2001b)Constitutive model with FEM focuses on formabilityBased on Kawabata et al. (1973)Xue et al. (2003) and Peng (2003)Focus on constitutive model and incorporation into FEMUse of shell elements and nonorthogonalityACMTRLDetails 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

  • State of the Art FEMCherouat and Billot (2001)Truss elements towsMembrane elements resinSidhu et al. (2001)Truss elements towsShell elements inter-tow friction and fiber angle jammingLi et al. (2004) [@ UML]Truss elements towsShell elements increasing tangent shear modulus

    ACMTRLDetails 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. UMLTruss ElementsShell ElementFabric unit cell

  • State of the Art FEMReaction force comparison between fabric friction model and Coulomb friction model

    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. UMLFabric friction model, m=f(H)Coulomb friction model, m=0.3

  • VisionAbility 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 propertiesTemperatureFriction propertiesMaterial types and weaves

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

  • Perceived GapsResearchers have determined modeling techniques for specific materials, weave types and casesThese methods need to be extended to include generic materials, weave types and cases

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

  • Research ThrustsCollaborative research among modeling laboratories:Comparison and interpretation of differences in results among different modeling techniquesJoining of different fabric models, such as friction and constitutive, in model of forming processes and interpretation and publication of resultsUse these methods to lead to models for generic materials, weaves and cases

  • Research ThrustsCollaborative research among testing laboratories:Comparison and interpretation of differences in results using different test proceduresUse these comparisons to work towards standardization of tests and to determine strengths and weaknesses of the different tests that are available

  • Collaborative Research: James SherwoodJennifer Gorczyca University of Massachusetts Lowell

    Collaborators: Northwestern University

    Enhancing the Understanding of the Fundamental Mechanisms of Thermostamping Woven Composites to Develop a Comprehensive Design ToolNSF Grant Number: DMI- 0331267NSF/DOE/APC Workshop: Future of Modeling in Composites Molding Processes (Design & Optimization Session)9-10 June 2004Arlington, Virginia