Predictive modelling for optimization of textile composite forming

Wrinkling often occurs during textile composite forming and is a major problem for manufacturers. The prediction of this defect is, therefore, of major importance for the design and optimization of textile composite structures. Numerical simulations of forming for textile composites over a hemisphere have been conducted using a rate/temperature-dependent hybrid FE model. The hybrid FE model incorporates a fully predictive multi-scale energy model which determines the shear resistance of the textile composite sheet. The effects of varying the normal force distribution across the edges of the blank and blank size, together with the effect of changes in forming temperature on the final fibre pattern and wrinkling behaviour, are investigated. Predictions are evaluated against press-formed components. The results from the simulation and the experiments have good correlation and show that wrinkling can be minimized by optimizing the force distribution around the edge of the manufacturing tool and by careful choice of forming temperature.