A new procedure for Finite Element simulation of forming process of non-homogeneous composite laminates and FMLs

A new method is presented to model the interactions between aluminum/composite and composite/composite layers in the Finite Element Method (FEM) simulation of forming processes of Fiber Metal Laminates (FMLs) and inhomogeneous composite laminates. Finite Element simulation is based on a thermo-viscoelastic material model. The method divides the composite laminates and FMLs into continuum and homogeneous aluminum and composite layers and polymeric layers between them. The polymeric layer has a rigid contact to the aluminum and composite layers and its shear strains result in relative displacements of the laminates and creates the required deformations. The method is applied to a press forming simulation of composite laminates (PVC/woven glass fabric) and related FMLs at 140 °C and 160 °C. The simulation is carried out using ABAQUS explicit FE package and the results of mechanical and thermal simulations are compared with experimental results. The results demonstrate the accuracy of this method that models the interactions in the forming simulations of composite laminates and FMLs.