The theoretical prediction of thermoformed carbon fibre reinforced thermoplastic materials in support of optimal process design

Research output: Chapter in Book/Report/Conference proceedingConference contribution

Abstract

This paper develops a theoretical model capable of predicting the deformation behaviour of a thermoplastic composite, 90° angled part during manufacture using a thermoforming process. The model is intended to support a virtual approach to understanding process capability. This in turn will increase the utility of digital manufacturing methods by enabling the use of more realistic part forms in product and process design. A typical V-shape carbon fibre reinforced polyphenylene sulfide (PPS) composite part was selected as the demonstrator. A custom built thermoforming cell was used to manufacture a series of samples to investigate the process-induced shape variation of the part based on a range of tooling temperatures during cooling. It was found that the influence of mould temperature on the deformation is more dependent on the composite's thermal properties. After de-moulding, the part deforms because of the thermal and crystallization shrinkage during the cooling from mould temperature to room temperature. For the same ply orientation, the final bend angles decrease with increasing mould temperature. The processing conditions were then used as the basis of a theoretical model designed to predict the final part angle. The theoretical model was developed according to basic equilibrium, compatibility, and constitutive equations. The displacement model was supplemented with boundary and continuity conditions to solve final laminate deformations. In the constitutive model, thermal and crystallization shrinkage strains are considered because of semi-crystalline and very low moisture absorption properties of PPS. The stiffness matrix is considered as temperature dependent as the behaviour of PPS is highly temperature dependant. The largest difference between experimental and predicted results was 16.26% for the sample formed at the 170°C mould temperature whereas the calculation outcome for the sample formed with 110°C mould was within 1.44% of the experimental result. The calculations show that composite part deformation is dominated by temperature change induced anisotropic thermal strains.

Original languageEnglish
Title of host publication11th AIAA Aviation Technology, Integration, and Operations (ATIO) Conference, including the AIAA Balloon Systems Conference and 19th AIAA Lighter-Than-Air Technology Conference
DOIs
Publication statusPublished - 2011
Event11th AIAA Aviation Technology, Integration, and Operations (ATIO) Conference, including the AIAA Balloon Systems Conference and 19th AIAA Lighter-Than-Air Technology Conference 2011 - Virginia Beach, VA, United States
Duration: 20 Sep 201122 Sep 2011

Publication series

Name11th AIAA Aviation Technology, Integration,and Operations (ATIO) Conference, including the AIAA Balloon Systems Conference and 19th AIAA Lighter-Than-Air Technology Conference

Conference

Conference11th AIAA Aviation Technology, Integration, and Operations (ATIO) Conference, including the AIAA Balloon Systems Conference and 19th AIAA Lighter-Than-Air Technology Conference 2011
Country/TerritoryUnited States
CityVirginia Beach, VA
Period20/09/201122/09/2011

Bibliographical note

Funding Information:
I would like to acknowledge the Department for Employment and Learning (DEL) for funding the All Island programme as well as the China Scholarship Council for their financial support.

Copyright:
Copyright 2013 Elsevier B.V., All rights reserved.

ASJC Scopus subject areas

  • Aerospace Engineering
  • Energy(all)

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