Multi-scale finite element analysis of laser-assisted forming of CF/PEEK composite corner structures

Laser-assisted forming can significantly increase the forming efficiency of thermoplastic composites. However, when forming CF/PEEK curved corner structures using laser-assisted forming, bending spring-back generated by the prepreg tape constrains the shape accuracy of the component. The bending deformation of unidirectional resin matrix composite materials is highly nonlinear. In this study, a multi-scale finite element method is used to obtain the bending properties of CF/PEEK composites for bending spring-back phenomenon of thermoplastic composite samples and predict the spring-back angle of CF/PEEK corner structures fabricated via laser-assisted forming. The average material properties were first calculated using RVE. Following this, a mesoscale model was developed to analyze kink deformation of the composite. Finally, the macroscopic prepreg bending spring-back was calculated. It was determined that the main mechanism of corner forming corresponds to the occurrence of a fiber kinking phenomenon on the interior of the corner. Furthermore, spring-back deformation is caused by residual stresses resulting from insufficient fiber kinking. The accuracy of the simulation results is verified via corner forming experiments. This study contributes to a deeper understanding of the spring-back mechanisms of laser-assisted forming of corner structures and provides a theoretical guidance for precision forming of multilayer thermoplastic composite bent structures.