Title: An iterative approach for the determination of tailored blanks for waste-free composite forming by means of FE forming simulation

Authors: Dominik Dörr; Lukas Lipowsky; Fabian J. Schirmaier; Luise Kärger; Frank Henning

Addresses: Karlsruhe Institute of Technology (KIT), Institute of Vehicle System Technology (FAST), Department of Lightweight Technology (LBT), 76131 Karlsruhe, Germany ' Karlsruhe Institute of Technology (KIT), Institute of Vehicle System Technology (FAST), Department of Lightweight Technology (LBT), 76131 Karlsruhe, Germany ' Karlsruhe Institute of Technology (KIT), Institute of Vehicle System Technology (FAST), Department of Lightweight Technology (LBT), 76131 Karlsruhe, Germany ' Karlsruhe Institute of Technology (KIT), Institute of Vehicle System Technology (FAST), Department of Lightweight Technology (LBT), 76131 Karlsruhe, Germany ' Karlsruhe Institute of Technology (KIT), Institute of Vehicle System Technology (FAST), Department of Lightweight Technology (LBT), 76131 Karlsruhe, Germany; Fraunhofer Institute for Chemical Technology, Polymer Engineering Department, 76327 Pfinztal, Germany

Abstract: Forming of composite pre-products into complexly shaped geometries is one of the most determining process steps in the manufacturing of continuously fibre-reinforced composites. An educated guess of the tailoring of the pre-product (tailored blank), which leads to the desired contour after forming, is in the most cases not possible. An iterative and a direct approach, which facilitate the determination of a tailored blank, based on finite element forming simulation, are presented. Both approaches are successfully applied to a box-shaped, generic geometry and thermoplastic UD-tapes, as well as to a light pod of an automotive boot-lid and a woven engineering textile. It is shown, that the iterative approach is necessary for a reliable determination of a tailored blank, if there is an influence of the areas outside the desired contour for the non-tailored blanks.

Keywords: composite forming; process simulation; finite element analysis; finite element forming simulation; iterative tailoring determination.

DOI: 10.1504/IJAUTOC.2017.091427

International Journal of Automotive Composites, 2017 Vol.3 No.2/3/4, pp.323 - 338

Received: 24 Jan 2017
Accepted: 30 Nov 2017
Published online: 30 Apr 2018 *

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