Simulation and experimental study on thermal deep drawing of carbon fiber woven composites

• Picture frame test, thermal deep drawing experiments and simulation were conducted.
• Compression and shear between fiber bundles are the main deformation mechanism of carbon fiber woven deformation.
• The maximum shear angle for composites in this study is 33°.
• The optimal forming temperature is approximately 170 °C.

Carbon fiber woven composites are composed of carbon fiber woven and resin matrix. To reduce the manufacture cost, thermal stamping, a new forming technology, was proposed and investigated to fabricate composite part. The mechanical properties of carbon fiber have great influence on the deformation of carbon fiber composites. In this study, shear angle–displacement curves and shear load–shear angle curves were obtained from picture frame test. Thermal deep drawing experiments and simulation were conducted, and the shear load–displacement curves under different forming temperatures and shear angle–displacement curves were obtained. The results show the compression and shear between fiber bundles are the main deformation mechanism of carbon fiber woven composite. The maximum shear angle for the composites in this study is 33°. In the drawing process, the forming temperature affects the drawing force, which drops rapidly with the increasing temperature. The suitable forming temperature in deep drawing of the carbon fiber woven composite is approximately 170 °C.