Finite element simulations of laminated composite forming processes

Continuous Fibre Reinforced Polymers (CFRPs) combine strength and stiffness of fibres with the design flexibility of polymeric matrix materials. Fast production methods like thermo-folding, diaphragm forming or stamping can produce large numbers of CFRP components in a cost efficient way. Pre-consolidated laminates are heated above their melting temperature and subsequently re-shaped. These forming processes can introduce unacceptable shape distortions such as springback, wrinkling or tearing. The objective of this research is the development of a design tool for high precision CFRP components made from multi-layer laminates. Optimisation of the CFRP design and the forming process reduces costly trial-and-error procedures and can significantly shorten the time-to-market. This requires a predictive model that is robust, accurate and fast. Such an all-encompassing procedure is not readily available.