An iterative approach for the determination of tailored blanks for waste-free composite forming by means of FE forming simulation. (2017)

• Record Type: Journal Article
• Authors: Dörr, Dominik; Lipowsky, Lukas; Schirmaier, Fabian J.; Kärger, Luise; Henning, Frank
• Is Part Of: International journal of automotive composites. Volume 3:Number 2/3/4(2017)
• Page Start: 323
• Page End: 338
• Publication Date: 2017
• Subjects: composite forming -- process simulation -- finite element analysis -- finite element forming simulation -- iterative tailoring determination; Composite materials in automobiles -- Periodicals; 629.232
• Languages: English
• ISSNs: 2051-8218

Abstract

Forming of composite pre-products into complexly shaped geometries is one of the most determining process steps in the manufacturing of continuously fibre-reinforced composites. An educated guess of the tailoring of the pre-product (tailored blank), which leads to the desired contour after forming, is in the most cases not possible. An iterative and a direct approach, which facilitate the determination of a tailored blank, based on finite element forming simulation, are presented. Both approaches are successfully applied to a box-shaped, generic geometry and thermoplastic UD-tapes, as well as to a light pod of an automotive boot-lid and a woven engineering textile. It is shown, that the iterative approach is necessary for a reliable determination of a tailored blank, if there is an influence of the areas outside the desired contour for the non-tailored blanks.