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Collaborative Research:Collaborative Research:

James SherwoodJames SherwoodJennifer Gorczyca Jennifer Gorczyca

University of Massachusetts University of Massachusetts Lowell Lowell

Collaborators: Collaborators: Northwestern UniversityNorthwestern University

Enhancing the Understanding of the Enhancing the Understanding of the Fundamental Mechanisms of Thermostamping Fundamental Mechanisms of Thermostamping

Woven Composites to Develop a Woven Composites to Develop a Comprehensive Design ToolComprehensive Design Tool

NSF Grant Number: NSF Grant Number: DMI- 0331267DMI- 0331267

NSF/DOE/APC Workshop: Future of Modeling in Composites Molding Processes

(Design & Optimization Session)9-10 June 2004

Arlington, Virginia

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MotivationMotivation

Mass production of lightweight low-cost Mass production of lightweight low-cost woven-fabric reinforced composite woven-fabric reinforced composite partsparts

Desirable in automobiles for:Desirable in automobiles for: High strength-to-weight ratio (compared to High strength-to-weight ratio (compared to

metal counterparts)metal counterparts) Reduce weight Reduce weight Increase fuel efficiency Increase fuel efficiency

Development of predictive design toolDevelopment of predictive design tool

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Motivation – Motivation – ThermostampingThermostamping

Punch

Binder Ring

Fabric

Die

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Motivation – Part QualityMotivation – Part Quality

[Wilks, 1999]

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Our Research:Our Research: Development of a friction model to capture Development of a friction model to capture

the behavior of balanced plain-weave the behavior of balanced plain-weave composite materials during thermoformingcomposite materials during thermoforming

Incorporation of the friction model into the Incorporation of the friction model into the commercial finite element code ABAQUScommercial finite element code ABAQUS

Parametric study of the effect of processing Parametric study of the effect of processing parameters on the reaction force on the parameters on the reaction force on the punchpunch

Use of the fabric friction model with a fabric Use of the fabric friction model with a fabric constitutive model in a commercial finite constitutive model in a commercial finite element code such as ABAQUS to create a element code such as ABAQUS to create a predictive tool predictive tool

ACMTRLACMTRLACMTRLACMTRL Our Our Research:Research:

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Our Research:Our Research:

HH Hersey Hersey

NumberNumber

use Power use Power Law viscosity Law viscosity modelmodel

UU fabric velocity fabric velocity

WW normal force normal force

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State of the Art – State of the Art – Testing StandardsTesting Standards

Study of metal/fabric interface Study of metal/fabric interface relatively newrelatively new

ASTM standards exist to determine ASTM standards exist to determine friction coefficients of sheets friction coefficients of sheets Account for normal load and pull-out Account for normal load and pull-out

velocity velocity Do not account for sheet viscosity and Do not account for sheet viscosity and

fiber orientationfiber orientation Researchers have developed their Researchers have developed their

own test methods (many based on own test methods (many based on ASTM Standard D 1894)ASTM Standard D 1894)

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State of the Art – Friction State of the Art – Friction TestingTesting

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

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State of the Art – FEMState of the Art – FEM

Boisse Boisse et al.et al. (1996, 2001a, 2001b) (1996, 2001a, 2001b) Constitutive model with FEM focuses on Constitutive model with FEM focuses on

formabilityformability Based on Kawabata Based on Kawabata et al.et al. (1973) (1973)

Xue Xue et al.et al. (2003) and Peng (2003) (2003) and Peng (2003) Focus on constitutive model and Focus on constitutive model and

incorporation into FEMincorporation into FEM Use of shell elements and nonorthogonalityUse 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

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State of the Art – FEMState of the Art – FEM Cherouat and Billoët Cherouat and Billoët

(2001)(2001) Truss elements – towsTruss elements – tows Membrane elements – resinMembrane elements – resin

Sidhu Sidhu et al.et al. (2001) (2001) Truss elements – towsTruss elements – tows Shell elements – inter-tow Shell elements – inter-tow

friction and fiber angle friction and fiber angle jammingjamming

Li Li et al.et al. (2004) [@ UML] (2004) [@ UML] Truss elements – towsTruss elements – tows Shell elements – increasing Shell elements – increasing

tangent shear modulustangent shear modulusDetails 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

Truss Element

s

Shell Element

Fabric unit cell

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State of the Art – FEMState of the Art – FEM

0

200

400

600

800

1000

1200

0.0 0.2 0.4 0.6 0.8 1.0

Time, s

Re

act

ion

Fo

rce

on

Pu

nch

, N

0.5V, Fabric friction model 0.5V, Coulomb friction model

0

500

1000

1500

2000

2500

3000

3500

0.0 0.1 0.2 0.3 0.4 0.5

Time, s

Re

act

ion

Fo

rce

on

Pu

nch

, N

V, Fabric friction model V, Coulomb friction model 0

5000

10000

15000

20000

25000

0.00 0.05 0.10 0.15 0.20 0.25

Time, s

Re

act

ion

Fo

rce

on

Pu

nch

, N

2V, Fabric friction model 2V, Coulomb friction model

Reaction 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. UML

Fabric friction model, =f(H)

Coulomb friction model, =0.3

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VisionVision Ability to compare results from different testing Ability to compare results from different testing

methods is important (i.e. shear frame and bias methods is important (i.e. shear frame and bias extension, and friction)extension, and friction)

Researchers must combine finite element Researchers must combine finite element modeling and testing efforts to create a robust modeling and testing efforts to create a robust Design Tool for thermoforming of woven-fabric Design Tool for thermoforming of woven-fabric composite materialscomposite materials

Analytical Design Tool will account for changing:Analytical Design Tool will account for changing: Constitutive propertiesConstitutive properties TemperatureTemperature Friction propertiesFriction properties Material types and weavesMaterial types and weaves

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VisionVision

Continue to collaborate with industry Continue to collaborate with industry to:to: Ensure that the appropriate materials Ensure that the appropriate materials

and processing techniques are being and processing techniques are being investigated investigated

Aid technology transfer from academia Aid technology transfer from academia to industryto industry

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Perceived GapsPerceived Gaps

Researchers have determined Researchers have determined modeling techniques for specific modeling techniques for specific materials, weave types and casesmaterials, weave types and cases

These methods need to be extended to These methods need to be extended to include “generic” materials, weave include “generic” materials, weave types and casestypes and cases

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Perceived GapsPerceived Gaps

Researchers have developed their own Researchers have developed their own testing methods (true for constitutive testing methods (true for constitutive property research and friction modeling)property research and friction modeling)

Work with ASTM for standardized test protocolsWork with ASTM for standardized test protocols Analytical methods for comparing test data Analytical methods for comparing test data

using different test procedures must be using different test procedures must be proposed, publicized and peer-reviewedproposed, publicized and peer-reviewed

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Research ThrustsResearch Thrusts Collaborative research among Collaborative research among

modeling laboratories:modeling laboratories: Comparison and interpretation of Comparison and interpretation of

differences in results among different differences in results among different modeling techniquesmodeling techniques

Joining of different fabric models, such Joining of different fabric models, such as friction and constitutive, in model of as friction and constitutive, in model of forming processes and interpretation forming processes and interpretation and publication of resultsand publication of results

Use these methods to lead to models for Use these methods to lead to models for “generic” materials, weaves and cases“generic” materials, weaves and cases

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Research ThrustsResearch Thrusts

Collaborative research among testing Collaborative research among testing laboratories:laboratories: Comparison and interpretation of Comparison and interpretation of

differences in results using different test differences in results using different test proceduresprocedures

Use these comparisons to work towards Use these comparisons to work towards standardization of tests and to standardization of tests and to determine strengths and weaknesses of determine strengths and weaknesses of the different tests that are availablethe different tests that are available

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Collaborative Research:Collaborative Research:

James SherwoodJames SherwoodJennifer Gorczyca Jennifer Gorczyca

University of Massachusetts University of Massachusetts Lowell Lowell

Collaborators: Collaborators: Northwestern UniversityNorthwestern University

Enhancing the Understanding of the Enhancing the Understanding of the Fundamental Mechanisms of Thermostamping Fundamental Mechanisms of Thermostamping

Woven Composites to Develop a Woven Composites to Develop a Comprehensive Design ToolComprehensive Design Tool

NSF Grant Number: NSF Grant Number: DMI- 0331267DMI- 0331267

NSF/DOE/APC Workshop: Future of Modeling in Composites Molding Processes

(Design & Optimization Session)9-10 June 2004

Arlington, Virginia