Composite forming simulation for non-crimp fabrics based on generalized continuum approaches – AMECOMP : Abschlussbericht / Final project report (DFG 431354059 / ANR-19-CE06-0031)

Abstract

Continuously carbon fiber reinforced composites are increasingly used for structural applications in various fields of engineering due to their excellent weight-specific mechanical properties. Non-crimp-fabrics (NCF) provide the highest lightweight potential as reinforcement for the composite due to their straight fibers, compared to woven fabrics with undulated fibers. NCFs are made of one (UD-NCF), two (Biax-NCF) or more directions of fibers linked together with a polymer stitching in specific patterns. The deformation behavior of NCFs is challenging due to the interaction between the fibers and the stitching, which also results in a higher susceptibility to forming effects such as roving slippage, fiber waviness and gapping compared to woven fabrics. The aim of the AMECOMP project was to improve the understanding of the forming behavior of NCFs and to develop suitable simulation models to broaden the range of potential applications. Mesoscopic models that accurately describe the architecture of the NCF were developed for virtual material characterization and detailed analysis of forming defects in critical areas. Macroscopic models that describe the relevant deformation mechanisms of NCF in a homogenized way were developed for efficient analysis of large components and multi-layer stacks.