Advancing the application of tailored blanks by developing an integrated process design tool that is able to predict the final consolidation quality of a stamp formed tailored blank based on the processing parameters, material parameters and the initial state of the material.
Keywords: consolidation, void content, stamp forming, advanced fiber placement
Currently, the application of stamp forming mainly concerns secondary parts of limited complexity. The parts have simple geometries, with a uniform thickness and a uniform fiber orientation. Further optimized designs are required to extend the application of thermoplastic composite materials to structurally loaded primary parts, to increase weight savings and to reduce costs. These designs require tailored lay-ups in terms of thickness and fiber orientation with respect to their application. The combination of advanced fiber placement (AFP) and stamp forming provides the opportunity to move into this area of primary structures.
The performance of a stamp formed component is largely governed by its consolidation quality. Consolidation quality comprises many properties, such as void content, crystallinity and interlaminar bond strength. These properties strongly depend on the local thermal and pressure history of the component during the stamp forming process, as well as the initial state of the material. Consequently, the consolidation quality may improve or deteriorate during processing of the material and may, moreover, vary from place to place. In order to manufacture high quality tailored components in a cost-effective and energy efficient manner optimization of the stamp forming processes is required. For this purpose an integrated process design tool needs to be developed that is able to predict the final consolidation quality based on the processing and material parameters and the initial state of the material.
The critical mechanisms governing the consolidation quality of stamp formed thermoplastic composites are identified by means of experiments. These mechanisms are described by well-known models from literature or newly developed models. The models are combined into a material state model, which can describe the state of the material as a function of the local thermal and pressure history of the tailored blank. This model is coupled with a stamp forming process model. Together, this will result in an integrated process design tool, which will be used to derive processing and material guidelines for stamp forming of thermoplastic composite tailored blanks.
This process route was demonstrated on a tailored spar section, which was presented at the ITHEC 2018 Conference in Bremen. During ITHEC 2018 Tjitse Slange received the ITHEC / JEC Best Paper Award for his paper about “Rapid Manufacturing of a Tailored Spar by AFP and Stamp Forming”.
Watch the video Rapid Manufacturing of a Tailored Spar
- Interested in application of the developed knowledge? Please contact Sebastiaan Wijskamp.
- Interested in the underlying scientific background? Please contact Tjitse Slange.
- New thermoplastic composites materials
- Resin Systems
- Molding Compounds
- Fiber Placement
- Press Forming
- Welding Technologies
- Metal composite joints