Forming simulation sensitivity study of the double-dome benchmark geometry

Simulations of manufacturing processes are of utmost importance in order to check on process feasibility of composites products already during the design phase. In order to benchmark the different software for (thermo)forming simulations of textiles and composites a benchmark geometry was agreed during previous Esaform conferences. Round 2 results have led to the insight that a stronger definition of the benchmark was needed, see [1]. The geometry, referred to as double-dome, combines doubly curved regions with steep walls and small radii. Therefore it may be considered critical with respect to forming behavior. As testing material a Twintex comingled glass/PP both as plain and twill weave woven fabric were chosen [2]. This paper addresses the simulation of the double-dome with the finite-element software Aniform. Shear angles, draw-in and the possible presence of wrinkles will be taken into account and compared to round 2 results of other participants. Additionally, a numerical sensitivity study of material and process parameters will be presented in order to identify major influences on the forming results. The paper concludes with a number of recommendations for further research as well as possible improvements for numerical modeling. [1] Sargent et.al., “Benchmark study of finite element models for simulation the thermostamping of woven-fabric reinforced composites”. Proceedings of the 13th Esaform Conference, Brescia 2010. [2] Cao et.al., “Characterisation of mechanical behaviour of woven fabrics: experimental methods and benchmark results”, Composites Part A: Applied Science and Manufacturing, 2008