Scope of the presented work is a detailed comparison of a macroscopic draping model with real fibre architecture on a complex non-crimp-fabric preform using a new robot-based optical measurement system. By means of a preliminary analytical process design approach, a preforming test centre is set up to manufacture dry non-crimp-fabric preforms. A variable blank holder setup is used to investigate the effect of different process parameters on the fibre architecture. The real fibre architecture of those preforms is captured by the optical measurement system, which generates a three-dimensional model containing information about the fibre orientation along the entire surface of the preform. The measured and calculated fiber orientations are then compared with the simulation results in a three-dimensional overlay file. The results show that the analytical approach is able to predict local hot spots with high shear angles on the preform. Macroscopic simulations show a higher sensitivity towards changes in blank holder pressure than reality and limit the approach to precisely predict fibre architecture parameters on complex geometries.
AllaouiS. Experimental and numerical analyses of textile reinforcement forming of a tetrahedral shape. Compos Part A2011; 42: 612–622.
2.
HarrisonPGomesRCurado-CorreiaN. Press forming a 0/90 cross-ply advanced thermoplastic composite using the double-dome benchmark geometry. Compos A Appl Sci Manuf2013; 54: 56–69.
3.
BelSHamilaNBoisseP. Finite element model for NCF composite reinforcement preforming: importance of inter-ply sliding. Compos A Appl Sci Manuf2012; 43: 2269–2277.
4.
Boisse P and Hamila N. Modelling composite reinforcement forming processes. In: Boisse P (ed.) Composite reinforcements for optimum performance. Cambridge: Woodhead Publishing Limited, 2011, pp.651-671.
5.
GerekeTDöbrichOHübnerM. Experimental and computational composite textile reinforcement forming: a review. Compos A Appl Sci Manuf2013; 46: 1–10.
6.
LinHWangJLongAC. Predictive modelling for optimization of textile composite forming. Compos Sci Technol2007; 67: 3242–3252.
7.
WillemsALomovSVVerpoestI. Drape-ability characterization of textile composite reinforcements using digital image correlation. Optics Lasers Eng2009; 47: 343–351.
8.
Miene A, Göttinger M and Herrmann AS. Quality assurance by digital image analysis for the preforming and draping process of dry carbon fiber material. In: SAMPE EUROPE international conference and forum, Paris, 31 March–2 April 2008.
9.
ZambalSPalfingerWStögerM. Accurate fibre orientation measurement for carbon fibre surfaces. Pattern Recogn2015; 48: 3324–3332.
10.
Nezami FN, Gereke T and Cherif C. Automated preforming of woven fabrics with segmented blank holders: a multi-scale experimental approach. In: Proceedings composite week @ Leuven and TexComp-11 conference, Leuven, 16–20 September 2013.
11.
VancloosterKLomovSVerpoestI. Experimental validation of forming simulations of fabric reinforced polymers using an unsymmetrical mould configuration. Compos A Appl Sci Manuf2009; 40: 530–539.
12.
Graf M. Method and apparatus for producing a three-dimensional preform in the course of manufacturing fiber-reinforced moldings. Patent DE 2010 10043666, Germany, 2010.
13.
Dieffenbacher Maschinen und Anlagenbau GmbH. Draping for producing a three-dimensional preform of fibrous material. Patent DE 2013 2010 4091, Germany, 2013.
14.
Harries M and Ströhlein T. Apparatus and method for draping of flat semi-finished products for producing a fibrous composite material. Patent DE 2013 10007382, Germany, 2013.
15.
Eberdt C, Klumpp S and Schröder M. Device, useful for producing complex three-dimensionally shaped fiber reinforced preform from two-dimensional planar fiber assembly, comprises molding tool with mold contour which maps the complex-dimensional shape of preform. Patent DE102010054933, Germany, 2010.
16.
Leutz D, Kluepfel M, Dumont F, et al. FE-Simulation of the Diaphragm Draping Process for NCF on a Macro-Scale Level. In: The 14th international ESAFORM conference on material forming, Belfast, 27–29 April 2011.
17.
NezamiFNGerekeTCherifC. Analyses of interaction mechanisms during forming of multilayer carbon woven fabrics for composite applications. Compos A Appl Sci Manuf2016; 84: 404–416.
18.
LeeJHongSYuW. The effect of blank holder force on the stamp forming behavior of non-crimp-fabric with a chain stitch. Compos Sci Technol2007; 67: 357–366.
19.
Nezami FN. Automated preforming of carbon-fibre reinforcements with active forming manipulation for the manufacturing of complex shaped composite components. Technische Universität Dresden, 2015.
20.
CapelleEOuagnePSoulatD. Complex shape forming of flax woven fabrics: design of specific blank-holder shapes to prevent defects. Compos B Eng2014; 62: 29–36.
21.
PengXRehmanZU. Textile composite double dome stamping simulation using a non-orthogonal constitutive model. Compos Sci Technol2011; 71: 1075–1081.
22.
Guzman-MaldonadoEHamilaNNaouarN. Simulation of thermoplastic prepreg thermoforming based on a visco-hyperelastic model and a thermal homogenization. Mater Design2016; 93: 431–442.
23.
PazminoJMathieuSCarvelliV. Numerical modelling of forming of a non-crimp 3D orthogonal weave E-glass composite reinforcement. Compos A Appl Sci Manuf2015; 72: 207–218.
24.
Margossian. Finite element forming simulation of locally stitched non-crimp fabrics. Compos A Appl Sci Manuf2014; 61: 152–162.
25.
TavanaRNajarSAbadiM. Meso/macro-scale finite element model for forming process of woven fabric reinforcements. J Compos Mater2012; 47: 2075–2085.
26.
PickettACreechGde LucaP. Simplified and advanced simulation methods for prediction of fabric draping. Eur J Computat Mech2005; 6: 677–691.
27.
Johnson A, Keilig T and Pickett A. Numerische Simulation des Formgebungsprozesses von endlosfaserverstärkten Thermoplasten. In: Werkstoffwoche 96, Symposium 8: Simulation, Modellierung, Informationssysteme, Stuttgart, 28–31 Mai 1996.
28.
Dumont F, Weimer C, Soulat D, et al. Composites preforms simulations for helicopters parts. In: Proceedings of the 11th ESAFORM conference on material forming, Lyon, 2008.
29.
Härtel F. Entwicklung eines Vorentwurfansatzes für die automatisierte Drapierung von Faserhalbzeugen, Doktor Hut Verlag, 2015.
30.
Böhler P, Michaelis D, Heieck F, et al. Numerical prediction and experimental validation of triaxially braided fibre architecture on curved mandrels. In: Proceedings. Composites Week @ Leuven and TexComp-11 Conference. Leuven, 16–20 September 2013.
31.
SchindelinJArganda-CarrerasIFriseE. Fiji: an open-source platform for biological-image analysis. Nat Meth2012; 9: 676–682.
32.
Mallach A, Kharchi K and Täger O. Neue Methoden zur Simulation des Drapierverhaltens textiler Halbzeuge für automobile Faser-Kunststoff-Verbund-Strukturen. In VDI K (2014). Kunststoffe im Automobilbau, Mannheim, 2–3 April 2014.
