Stretch Forming Simulation of Woven Composites Based on an Orthotropic Non-Linear Material Model

Abstract

Characterisation experiments have been conducted on a woven self-reinforced polypropylene composite (SRPP) including uniaxial and bias extension tests. Outcomes of these experiments were employed to develop a non-linear orthotropic material model within an incremental deformation framework. The material model of the woven composite was implemented into a finite element simulation to predict stretch forming behaviour of SRPP specimens. The predicted strain paths at the pole of specimens were verified against experimental outcomes. It was shown that specimens possessing different aspect ratios deform under a wide range of deformation modes from uniaxial extension to biaxial stretch modes. Finally, the effect of different forming parameters on the strain path evolution of the woven composite was elucidated through numerical simulations. It was shown that the aspect ratio of the samples plays an important role in forming behaviour of woven composites. Development of a reliable and accurate numerical model for predicting forming behaviour of woven composites and understanding their main forming mechanisms promote and encourage the extensive application of these materials systems in a wide range of mass producing industries. Adopting woven composites in manufacturing industrial components facilitates addressing environmental concerns such as recyclability and sustainability issues.