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Double Diaphragm Forming of a Discontinuous Advanced Composite Prepreg Material: Process Development and Material Modeling

[+] Author Affiliations
Christopher Munro, Daniel Walczyk, George Dvorak

Rensselaer Polytechnic Institute

Paper No. IMECE2005-82523, pp. 349-357; 9 pages
doi:10.1115/IMECE2005-82523
From:
  • ASME 2005 International Mechanical Engineering Congress and Exposition
  • Manufacturing Engineering and Materials Handling, Parts A and B
  • Orlando, Florida, USA, November 5 – 11, 2005
  • Conference Sponsors: Manufacturing Engineering Division and Materials Handling Division
  • ISBN: 0-7918-4223-1 | eISBN: 0-7918-3769-6
  • Copyright © 2005 by ASME

abstract

Due to their superior strength-to-weight ratios, advanced composite parts are increasingly being used by the aircraft industry. This industry is constantly looking for less costly, faster, and more reliable methods to produce advanced composite parts, while still maintaining the very high safety and reliability standards required. This paper describes a new SBCF (Stretch Broken Carbon Fiber) material being developed by Hexcel Corporation for use in forming of aerospace parts. The SBCF material is a discontinuous aligned fiber prepreg material that comes in unidirectional and woven forms. If commercialized, the SBCF material will expand the range of parts that can be formed using a double diaphragm forming (DDF) process. This paper also discusses the FEM modeling of the DDF process for the purposes of predicting part defects. Having defect prediction capabilities will reduce the time and money required to determine if a part can be formed using the SBCF material and DDF. A rudimentary orthotropic-viscoelastic model is developed for the SBCF material to be used in forming simulations being developed concurrently. Model parameters are derived from force-to-stretch (i.e. tensile tests run at a constant displacement rate) and relaxation experiments. A simple model for the diaphragm is developed and preliminary forming simulations are built. Early simulations include forming over hemi-ellipsoid and curved c-channel shapes.

Copyright © 2005 by ASME

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