Modelling of Process-Induced Deformation for Composite Parts Considering Tool-Part Interaction

• Main Authors: Wei Qiao, Weixing Yao
• Format: Article
• Language: English
• Published: MDPI AG 2020-10-01
• Series: Materials
• Subjects: fiber-reinforced polymer-matrix composites; finite element analysis; path-dependent model; process-induced deformation; tool-part interaction
• Online Access: https://www.mdpi.com/1996-1944/13/20/4503

Residual stresses are generated by tool-part interaction due to the large difference in the coefficients of thermal expansion (CTE) between the tool and the composite part, resulting in more process-induced part deformation. In this paper, a 3-D numerical model considering the influence of tool-part interaction is proposed to predict the deformation in complex-shape composite parts. In this numerical model, the existing path-dependent model is improved to consider the effect of tool-part interaction by adding the residual stress generated by tool-part interaction, and a simplified self-consistent micromechanics model is selected to predict the composite mechanical properties in the viscous and rubbery stages. The predicted and experimental spring-in angles of L- and U-shaped parts are compared. A good agreement shows the validity of the proposed numerical model. A parametric study is performed and the influence of part structural parameters on the spring-in angle is analyzed quantitatively. The results show that the spring-in angles caused by chemical shrinkage and tool-part interaction decrease with the increase of part thickness, but that caused by thermal contraction is almost constant.