ACMTRL Collaborative Research: James Sherwood Jennifer Gorczyca University of Massachusetts Lowell...
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Transcript of ACMTRL Collaborative Research: James Sherwood Jennifer Gorczyca University of Massachusetts Lowell...
ACMTRLACMTRL
Collaborative Research:Collaborative Research:
James SherwoodJames SherwoodJennifer Gorczyca Jennifer Gorczyca
University of Massachusetts University of Massachusetts Lowell Lowell
Collaborators: Collaborators: Northwestern UniversityNorthwestern University
Enhancing the Understanding of the Enhancing the Understanding of the Fundamental Mechanisms of Thermostamping Fundamental Mechanisms of Thermostamping
Woven Composites to Develop a Woven Composites to Develop a Comprehensive Design ToolComprehensive Design Tool
NSF Grant Number: NSF Grant Number: DMI- 0331267DMI- 0331267
NSF/DOE/APC Workshop: Future of Modeling in Composites Molding Processes
(Design & Optimization Session)9-10 June 2004
Arlington, Virginia
ACMTRLACMTRL
MotivationMotivation
Mass production of lightweight low-cost Mass production of lightweight low-cost woven-fabric reinforced composite woven-fabric reinforced composite partsparts
Desirable in automobiles for:Desirable in automobiles for: High strength-to-weight ratio (compared to High strength-to-weight ratio (compared to
metal counterparts)metal counterparts) Reduce weight Reduce weight Increase fuel efficiency Increase fuel efficiency
Development of predictive design toolDevelopment of predictive design tool
ACMTRLACMTRL
Motivation – Motivation – ThermostampingThermostamping
Punch
Binder Ring
Fabric
Die
ACMTRLACMTRL
Motivation – Part QualityMotivation – Part Quality
[Wilks, 1999]
ACMTRLACMTRL
Our Research:Our Research: Development of a friction model to capture Development of a friction model to capture
the behavior of balanced plain-weave the behavior of balanced plain-weave composite materials during thermoformingcomposite materials during thermoforming
Incorporation of the friction model into the Incorporation of the friction model into the commercial finite element code ABAQUScommercial finite element code ABAQUS
Parametric study of the effect of processing Parametric study of the effect of processing parameters on the reaction force on the parameters on the reaction force on the punchpunch
Use of the fabric friction model with a fabric Use of the fabric friction model with a fabric constitutive model in a commercial finite constitutive model in a commercial finite element code such as ABAQUS to create a element code such as ABAQUS to create a predictive tool predictive tool
ACMTRLACMTRLACMTRLACMTRL Our Our Research:Research:
ACMTRLACMTRL
Our Research:Our Research:
HH Hersey Hersey
NumberNumber
use Power use Power Law viscosity Law viscosity modelmodel
UU fabric velocity fabric velocity
WW normal force normal force
ACMTRLACMTRL
State of the Art – State of the Art – Testing StandardsTesting Standards
Study of metal/fabric interface Study of metal/fabric interface relatively newrelatively new
ASTM standards exist to determine ASTM standards exist to determine friction coefficients of sheets friction coefficients of sheets Account for normal load and pull-out Account for normal load and pull-out
velocity velocity Do not account for sheet viscosity and Do not account for sheet viscosity and
fiber orientationfiber orientation Researchers have developed their Researchers have developed their
own test methods (many based on own test methods (many based on ASTM Standard D 1894)ASTM Standard D 1894)
ACMTRLACMTRL
State of the Art – Friction State of the Art – Friction TestingTesting
ACMTRLACMTRL
Table from: Gorczyca, Sherwood and Chen (2004). Modeling of Friction and Shear in Thermostamping of Composites – Part I. Journal of Composite Materials. In Press.
ACMTRLACMTRLACMTRLACMTRL
State of the Art – FEMState of the Art – FEM
Boisse Boisse et al.et al. (1996, 2001a, 2001b) (1996, 2001a, 2001b) Constitutive model with FEM focuses on Constitutive model with FEM focuses on
formabilityformability Based on Kawabata Based on Kawabata et al.et al. (1973) (1973)
Xue Xue et al.et al. (2003) and Peng (2003) (2003) and Peng (2003) Focus on constitutive model and Focus on constitutive model and
incorporation into FEMincorporation into FEM Use of shell elements and nonorthogonalityUse of shell elements and nonorthogonality
Details can be found in: Gorczyca (2004). A study of the frictional behavior of a plain-weave fabric during the thermostamping process. Doctoral dissertation. Mechanical Engineering Dept. UML
ACMTRLACMTRLACMTRLACMTRL
State of the Art – FEMState of the Art – FEM Cherouat and Billoët Cherouat and Billoët
(2001)(2001) Truss elements – towsTruss elements – tows Membrane elements – resinMembrane elements – resin
Sidhu Sidhu et al.et al. (2001) (2001) Truss elements – towsTruss elements – tows Shell elements – inter-tow Shell elements – inter-tow
friction and fiber angle friction and fiber angle jammingjamming
Li Li et al.et al. (2004) [@ UML] (2004) [@ UML] Truss elements – towsTruss elements – tows Shell elements – increasing Shell elements – increasing
tangent shear modulustangent shear modulusDetails can be found in: Gorczyca (2004). A study of the frictional behavior of a plain-weave fabric during the thermostamping process. Doctoral dissertation. Mechanical Engineering Dept. UML
Truss Element
s
Shell Element
Fabric unit cell
ACMTRLACMTRL
State of the Art – FEMState of the Art – FEM
0
200
400
600
800
1000
1200
0.0 0.2 0.4 0.6 0.8 1.0
Time, s
Re
act
ion
Fo
rce
on
Pu
nch
, N
0.5V, Fabric friction model 0.5V, Coulomb friction model
0
500
1000
1500
2000
2500
3000
3500
0.0 0.1 0.2 0.3 0.4 0.5
Time, s
Re
act
ion
Fo
rce
on
Pu
nch
, N
V, Fabric friction model V, Coulomb friction model 0
5000
10000
15000
20000
25000
0.00 0.05 0.10 0.15 0.20 0.25
Time, s
Re
act
ion
Fo
rce
on
Pu
nch
, N
2V, Fabric friction model 2V, Coulomb friction model
Reaction force comparison between fabric friction model and Coulomb friction model
Details can be found in: Gorczyca (2004). A study of the frictional behavior of a plain-weave fabric during the thermostamping process. Doctoral dissertation. Mechanical Engineering Dept. UML
Fabric friction model, =f(H)
Coulomb friction model, =0.3
ACMTRLACMTRL
VisionVision Ability to compare results from different testing Ability to compare results from different testing
methods is important (i.e. shear frame and bias methods is important (i.e. shear frame and bias extension, and friction)extension, and friction)
Researchers must combine finite element Researchers must combine finite element modeling and testing efforts to create a robust modeling and testing efforts to create a robust Design Tool for thermoforming of woven-fabric Design Tool for thermoforming of woven-fabric composite materialscomposite materials
Analytical Design Tool will account for changing:Analytical Design Tool will account for changing: Constitutive propertiesConstitutive properties TemperatureTemperature Friction propertiesFriction properties Material types and weavesMaterial types and weaves
ACMTRLACMTRL
VisionVision
Continue to collaborate with industry Continue to collaborate with industry to:to: Ensure that the appropriate materials Ensure that the appropriate materials
and processing techniques are being and processing techniques are being investigated investigated
Aid technology transfer from academia Aid technology transfer from academia to industryto industry
ACMTRLACMTRL
Perceived GapsPerceived Gaps
Researchers have determined Researchers have determined modeling techniques for specific modeling techniques for specific materials, weave types and casesmaterials, weave types and cases
These methods need to be extended to These methods need to be extended to include “generic” materials, weave include “generic” materials, weave types and casestypes and cases
ACMTRLACMTRL
Perceived GapsPerceived Gaps
Researchers have developed their own Researchers have developed their own testing methods (true for constitutive testing methods (true for constitutive property research and friction modeling)property research and friction modeling)
Work with ASTM for standardized test protocolsWork with ASTM for standardized test protocols Analytical methods for comparing test data Analytical methods for comparing test data
using different test procedures must be using different test procedures must be proposed, publicized and peer-reviewedproposed, publicized and peer-reviewed
ACMTRLACMTRL
Research ThrustsResearch Thrusts Collaborative research among Collaborative research among
modeling laboratories:modeling laboratories: Comparison and interpretation of Comparison and interpretation of
differences in results among different differences in results among different modeling techniquesmodeling techniques
Joining of different fabric models, such Joining of different fabric models, such as friction and constitutive, in model of as friction and constitutive, in model of forming processes and interpretation forming processes and interpretation and publication of resultsand publication of results
Use these methods to lead to models for Use these methods to lead to models for “generic” materials, weaves and cases“generic” materials, weaves and cases
ACMTRLACMTRL
Research ThrustsResearch Thrusts
Collaborative research among testing Collaborative research among testing laboratories:laboratories: Comparison and interpretation of Comparison and interpretation of
differences in results using different test differences in results using different test proceduresprocedures
Use these comparisons to work towards Use these comparisons to work towards standardization of tests and to standardization of tests and to determine strengths and weaknesses of determine strengths and weaknesses of the different tests that are availablethe different tests that are available
ACMTRLACMTRL
Collaborative Research:Collaborative Research:
James SherwoodJames SherwoodJennifer Gorczyca Jennifer Gorczyca
University of Massachusetts University of Massachusetts Lowell Lowell
Collaborators: Collaborators: Northwestern UniversityNorthwestern University
Enhancing the Understanding of the Enhancing the Understanding of the Fundamental Mechanisms of Thermostamping Fundamental Mechanisms of Thermostamping
Woven Composites to Develop a Woven Composites to Develop a Comprehensive Design ToolComprehensive Design Tool
NSF Grant Number: NSF Grant Number: DMI- 0331267DMI- 0331267
NSF/DOE/APC Workshop: Future of Modeling in Composites Molding Processes
(Design & Optimization Session)9-10 June 2004
Arlington, Virginia