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Knowledge Based Cloud FE Simulation of Sheet Metal Forming Processes
Published on: December 13, 2016
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Integration of Material Characterization, Thermoforming Simulation, and As-Formed Structural Analysis for
Philip Bean1, Roberto A Lopez-Anido1, Senthil Vel1
1Advanced Structures and Composite Center, University of Maine, Orono, ME 04469, USA.
Polymers
|May 14, 2022
Summary
This study introduces a faster simulation method for thermoplastic composite thermoforming by integrating material characterization and structural analysis. This approach improves manufacturing accuracy and reduces design time for complex composite parts.
Area of Science:
- Materials Science
- Manufacturing Engineering
- Computational Mechanics
Background:
- Thermoplastic composite thermoforming is critical for manufacturing complex parts.
- Wrinkling during forming necessitates accurate simulation for process optimization.
- Existing material models for simulations are complex and time-consuming to develop.
Purpose of the Study:
- To propose an improved simulation-based thermoforming design process.
- To integrate material characterization and as-formed structural analysis.
- To simplify and expedite the manufacturing process for thermoplastic composites.
Main Methods:
- Developed experimental methods for measuring molten thermoplastic composite properties.
- Applied these properties to thermomechanical forming predictions using commercial simulation software.
- Tested a tool for using thermoforming simulations to inform structural models.
Main Results:
- Experimental methods expedited the acquisition of necessary material properties.
- Forming predictions showed improved agreement with experimental results compared to using representative properties.
- As-formed structural analysis produced results differing from idealized models, indicating its necessity in certain cases.
Conclusions:
- The proposed integrated approach enhances thermoplastic composite manufacturing.
- Simplified and expedited material characterization is achievable.
- As-formed structural analysis is crucial for accurate modeling in specific applications and warrants further investigation as an open-source alternative.
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