UNIVERSITY OF NOTTINGHAM

Workshop on Composite Sheet Forming

University of Massachusetts, Lowell, Sept 2001

Materials Characterisation for Composite Forming Dr Andrew Long

School of Mechanical, Materials, Manufacturing Engineering and Management University of Nottingham, Nottingham, UK

Contents
Why test? Deformation mechanisms Data required for forming simulations Available test methods Focus on intra-ply shear testing

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Materials Characterisation for Composite Forming

Why test ?
To determine formability of material To assess effects of process variables on forming To determine input data for simulations To validate simulations

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Deformation mechanisms
Textile composites

(a) Intra-ply shear

(b) Relative fibre slip

(c) Inter-ply slip

(d) Fibre buckling

(e) Fibre extension

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Simulation: Kinematic mapping

Surface model & initial fibre paths

Draped fibre pattern

Input data required: Start point & initial ply orientation Locking angle

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Simulation: Mechanical/FE approach

Input data required: Intra-ply shear modulus Matrix model viscosity (vs temp, rate) Ply/tool & ply/ply friction (vs temp, rate, pressure) Fibre moduli & ply bending stiffness Thermal properties

PAM-FORM ESI Software

What tests are available ?

Kawabata Evaluation System for Fabrics (KES-F)
KES-FB1: Tensile/shear
Tensile energy for 500gf/cm load Shear stiffness for 5o shear

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KES-FB2: Pure bending

Bending rigidity for 150o circular arc

KES-FB3: Compression
Energy for compression to 50gf/cm2

KES-FB4: Friction/Roughness

Coefficient of friction with steel wire Surface roughness (mean thickness variation)

Textile Protection & Comfort Center North Carolina State University

What tests are available ?

Intra-ply shear
Crosshead mounting
Fe Fe

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Clamping plate

Le We We Le

Bearings

Fe

Fe

Picture frame

Bias extension

What tests are available ?

In-plane tensile (uniaxial & biaxial)

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4 00 3 50 3 00 T en sio n (N /fil) Tension (N/thread) M che s eule 2 50 2 00 1 50 1 00 50 0 0 0 .2 5 k =2 Cas libre k =1 k =0.5

Yarn

LMSP ESEM - Orleans

1 direction free

weft K= warp

Strain (%)

0 .5 D form ation (% )

0 .7 5

What tests are available ?

Ply/tool and ply/ply friction
Normal Load (0.1-100kN) Composite Clamp Steel shim

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Heated Platen

Rear clamp Pre-consolidated composite Thermoco uple Steel shim

Test Rig at University of Limerick

Heated Platen

Side clamp

0.040 Shear Stress (MPa) 0.035 0.030 0.025 0.020 0.015 0.010

0.5mm/s 180C 0.5mm/s 220C 0.8mm/s 200C 1.2mm/s 180C 1.2mm/s 220C

0.5mm/s 200C 0.8mm/s 180C 0.8mm/s 220C 1.2mm/s 200C

Twintex 2x2 twill weave

0.005 0.0

0.5

1.0 1.5 2.0 Normal Pressure (MPa)

2.5

3.0

Bias extension
Key points: Aspect ratio (Length/Width) should be >=2 Very good way to determine locking angle (central region stops shearing) To find shear compliance, must video test & measure shear angle
Shear Angle
80 70 60 50 40 30 20 10 0

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PAM-FORM ESI Software

Bias extension: data analysis

120
250

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Force (N)

100

P800200 glass plain weave Specimen width 156mm (2:1 A.R.) 150 Rate = 100mm/min
100

Shear Force (N)

80

50

0 0 10 20 30 40 50 60 70 80 90

60
70

Displacement (mm)

40
Shear Angle (deg)

60 50 40 30 20 10

20

0 0

10
0 10

20
20 30 40

30
50 60

40
70 80

50
90

60

70

Shear Angle (deg) Displacement (mm)

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Bias extension vs picture frame shear

Surface Displacement Analysis (SDA)
Monitor speckle pattern movement Differentiation of displacement vector gives strain Strains are resolved along fibre directions

y
140mm

145mm

(a) Specimen

(b) Shear angle plot (degrees) at an intermediate stage

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Picture frame shear: woven fabrics

Plain, satin & twill weave glass
600

P800
500

S800-02 T800

Shear Force (N)

400

P800 Predicted S800-02 Predicted T800 Predicted

300

200

Effect of in-plane tension

500

100

0 0 10 20 30 40 50 60 70

400 80 300

P800 - 200 N

Locking angle = 66o

Shear Force (N)

Shear Angle (Deg)

P800 - 400 N

P800 - 800 N

Dry fabrics: No rate effects In-plane tension affects compliance & locking

200

Locking angle = 60o

100

0 0 10 20 30 40 50 60 70

Shear Angle (Deg)

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Picture frame shear: non-crimp fabrics

600

Ebx936 Parallel
500

Ebx936 Perpendicular

Shear Force (N)

400 300 200 100 0 0 10 20 30 40 50 60 70 200 80

+/-45o tricot 1&1 warp-knit (Ebx936)

Shear Angle (Deg) Ebx318 Parallel
160

Ebx318 Perpendicular

Shear Force (N)

+/-45o pillar warpknit (Ebx318)

120

80

40

0 0 10 20 30 40 50 60 70 80

Shear Angle (Deg)

Picture frame shear: non-crimp fabrics

600

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P800
500

S800-02

T800
Shear Force (N)
400

P800 Predicted

300

S800-02 Predicted

T800 Predicted

200

100

0 0 10 20 30 40 50 60 70 80

Shear Angle (Deg)

woven fabric

200

Ebx318 Parallel
160

Ebx318 Perpendicular

Shear Force (N)

120

80

40

0 0 10 20 30 40 50 60 70 80

Shear Angle (Deg)

45o warp-knitted fabric (chain stitch)

Picture frame shear: fabric locking angles

Ts/2

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Tw/2

Fabric ID
P150 T800 S800-02 P800 S800-01 Ebx318 Ebx936

Style
Plain weave 2:2 Twill weave 4 Harness Satin Plain weave 4 harness Satin Pillar NCF Tricot 1&1

Ply Angles
0/90 0/90 0/90 0/90 0/90 +/-45 +/-45

Surface Density (g/m2)

147 790 788 800 800 318 936

Tow Pitch (mm)

2.04 6.30 3.70 4.01 0.68 0.62 0.82

cos li =

Tw T Tow s

Width (mm)
1.22 4.40 2.80 3.09 0.62 0.47 0.70

Tow Width/ Pitch

0.60 0.70 0.76 0.77 0.91 0.77 0.86

Locking Angle (s.d.)

68o (-) 62o (1.7) 61o (1.6) 60o (1.4) 55o (1.7) 66o (-) 62o (-)

Tests carried out at 100 mm/min 200N pre-tension applied

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Picture frame shear: woven thermoplastic composite

25 50mm/min 300mm/min 20 500mm/min 1000mm/min 15

Shear Force (N)

10

Twintex 2x2 twill weave (190 oC)

0 0 10 20 30 40 50 60 70 80

Shear Angle

(o)

25 50mm/min 100mm/min 20 300mm/min 500mm/min 15 1000mm/min

Shear Force (N)

Specimen in environmental chamber

Twintex 2x2 twill weave (220 oC)

10

0 0 10 20 30 40 50 60 70 80

Shear Angle

(o)

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Picture frame shear: problems

6000

Compression Tension
Test 1 Test 2 Test 3 Test 4

Shear Force/Unit Length (N/m)

5000

Tension

4000

3000

2000

1000

0 0 10 20 30 40 50

Compression
60 70 80

Shear Angle (deg)

5 harness satin weave carbon/epoxy prepreg (4 repeats)

Sample misalignment can lead to: Tensile and/or compressive forces in tows Premature buckling of the sample

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Picture frame shear: woven prepreg

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Picture frame shear: woven prepreg

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Issues:
What materials properties are of interest? What properties and tests are required:
For formability assessment? For simulation?

What are effects of:

Process variables (rate, temperature)? Fabric architecture? Matrix rheology? Specimen size?

How repeatable are test methods? Can we propose a series of standard tests?