A Benchmark Study of Finite Element Codes for Forming Simulation of Thermoplastic UD-Tapes

For Finite Element (FE) simulation of composite thermoforming processes, either commercially available codes or multi-purpose FE solvers can be applied. In this work, the commercially available codes AniForm and PAM-FORM, as well as two approaches implemented in the multi-purpose FE solvers LS-Dyna and Abaqus are benchmarked in a comparative study. For this purpose, the final outer contour, as well as wrinkling behavior is analyzed in experimental forming studies and compared to the virtual predictions. It turns out, that FE forming simulation is capable to predict manufacturing defects. However, the capabilities and quality of the prediction of the considered tools differ.